Chevrolet - Trailblazer 4wd - Workshop Manual - 2002 - 2002

Page 15332 Conversion - English/Metric Page 1117 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Page 8631 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 454 For vehicles repaired under warranty, use the table. Disclaimer Page 13977 Driver Door Module (DDM) C2 Page 10977 1. Apply coolant to the end of the heater inlet hose. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 5260 Electrical Symbols Part 8 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 3391 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Page 10900 IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Page 9740 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 14924 Electrical Symbols Part 6 Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: By Symptom Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5226 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 4333 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 7033 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 13102 2. Remove the weatherstrip from the pinch flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure Page 3155 Conversion - English/Metric Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Evaporator Block Replacement - Auxiliary Expansion Block/Orifice Tube: Service and Repair Evaporator Block Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the torx studs from the evaporator block-auxiliary. 3. Remove the evaporator block-auxiliary (1) from the HVAC module-auxiliary. INSTALLATION PROCEDURE 1. Install the evaporator block-auxiliary (1) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the torx studs to the evaporator block-auxiliary. Tighten Tighten the studs to 14 N.m (124 lb in). 3. Install the HVAC module-auxiliary. Locations Fuel Pump Relay: Locations FUEL PUMP RELAY Locations View Page 4888 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 5905 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10089 17. Bleed the power steering system. 18. Adjust the front toe. Locations Locations View Page 11960 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1115 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 2526 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 6794 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. 13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. 14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. Page 5163 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 15368 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 9764 C101 Part 1 Page 5396 Fuel System Diagnosis - Steps 12-17 Frame Brace Replacement (Trailblazer EXT, Envoy XL) Structural Brace: Service and Repair Frame Brace Replacement (Trailblazer EXT, Envoy XL) Frame Brace Replacement (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the mounting bolts (2) from the frame brace (1). 3. Remove the frame brace (1) from the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the frame brace (1) to the frame using the mounting bolts (2). Page 15891 Electrical Symbols Part 6 Page 7060 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 3775 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 15582 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 3140 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 4982 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 175 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 15736 Equivalents - Decimal And Metric Part 1 Page 1543 Conversion - English/Metric Page 11478 13. Carefully remove the seat back cover from behind the trim edge of side impact air bag module. Important When separating the seat cover hook and loop retaining strip in the next step, do not pull the adhesive-backed strip from the pad. 14. Using a side-to-side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. 15. From the bottom of the seat back, place your hand up the front side of the seat back cover and release the hook and loop fasteners that attach the seat back cover to the foam pad. 16. Starting at the bottom of the seat back, remove the seat back cover by pulling the cover upwards. The bottom of the cover should be turning inside out as the cover rolls upwards. Important Do not remove the three hog rings that attach the cover to the foam pad. 17. Continue pulling the seat back cover upwards until the top of the seat belt retractor is accessible. 18. If equipped, disconnect the seat back heating element electrical connector. 19. Remove the two head restraint retainers from the top of the seat back. 20. Reposition the cover and pad as necessary. Page 11 Locations View Page 550 Control Module HVAC: Description and Operation BLOWER MOTOR CONTROL PROCESSOR The blower motor control processor controls the speed of the blower motor by increasing or decreasing the voltage drop on the ground side of the blower motor. The HVAC control module provides a low side pulse width modulated signal to the blower motor control processor over the blower motor speed control circuit. As the requested blower speed increases, the HVAC control module increases the amount of time that the speed signal is modulated to ground. As the requested blower speed decreases, the HVAC control module decreases the amount of time that the signal is modulated to ground. Specifications Timing Chain Guide: Specifications Timing Chain Tensioner Guide Bolt 124 inch lbs. Timing Chain Tensioner Shoe Bolt 18 ft. lbs. Timing Chain Top Guide Bolt 89 inch lbs. Page 8686 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 2578 Balancing Procedure Important: The refrigerant oil in the A/C system must be balanced during compressor replacement. 1. The replacement compressor is shipped with 240 ml (8.0 oz) of refrigerant oil. 2. Before installing the compressor, the refrigerant oil will have to be partially drained. 2.1. Refer to the amount of refrigerant oil recorded during the compressor removal. 2.2. Subtract the amount recorded from the total system capacity. Refer to Refrigerant System Capacities. The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor. 3. Drain the calculated amount of refrigerant from the replacement compressor. Disclaimer Driver Information Center - Setting Language Options Driver/Vehicle Information Display: All Technical Service Bulletins Driver Information Center Setting Language Options File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-015 Date: October, 2001 INFORMATION Subject: Understanding Driver Information Center Personalization/Language Options Models: 2002 Chevrolet and GMC SIT Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Driver Information Center Display (RPO U68) The Driver Information Center (DIC) display on the instrument cluster has a multi-lingual capability. A vehicle owner may accidentally put the DIC into a language he or she does not understand. This may make it difficult or impossible for the owner to figure out how to get the display back to the preferred language. This difficulty is resulting in clusters being replaced at the dealer as a warranty return. Dealers should reset the DIC back to the language that the owner understands by following these steps: 1. Press and hold the personalization button (2) and the trip information button (1) at the same time. The DIC will begin scrolling through the languages. Each language will be shown in that particular language (English will be in English, French will be in French, etc.). 2. When the preferred language appears, release both buttons. The DIC will then display the information in the language that was selected. Page 4334 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4971 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3678 Electrical Symbols Part 7 Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15909 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 622 1. Use the J 43244 in order to install the fog lamp relay to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 6480 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13891 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Locations Locations View Description and Operation Compass: Description and Operation The mirror uses two magnetic field sensors for compass direction. One sensor is for north and south, the other is for east and west. The mirror supplies a signal and low reference to each sensor. As the vehicle travels with or against the earth's magnetic pull, there will be a change in voltage on one or both sensors. As a result of the change in voltage, the mirror changes the heading on the compass display. Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 7736 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12736 Locations View Page 14348 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 8619 For vehicles repaired under warranty, use the table. Disclaimer Transfer Case Fluid Replacement (Trailblazer, Envoy) Fluid - Transfer Case: Service and Repair Transfer Case Fluid Replacement (Trailblazer, Envoy) Transfer Case Fluid Replacement (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the drain plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drain plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 3. Fill the transfer case with the proper fluid. Refer to Capacities - Approximate Fluid on page 4-255. Page 4733 IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2(TM), select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Page 4707 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Audio/A/C - Settings Change While Driving Body Control Module: Customer Interest Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14160 Sunroof / Moonroof Panel: Service and Repair Sunroof Sunshade Panel Replacement REMOVAL PROCEDURE 1. Remove the glass panel. 2. Remove the screws (1) that retain the water trough to the sunroof assembly. 3. Remove the water trough from the sunroof assembly from the top of the vehicle. IMPORTANT: The sunshade must be removed from the top of the vehicle. 4. Slide the sunshade forward. 5. Flex the center of the sunshade (2) upward while simultaneously sliding the panel sideways to release the retaining tabs (3) from the track slot (1). 6. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE Page 1546 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 64 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 7721 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8410 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 2911 10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve (117) from the engine block. 11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117). 12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. 13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. Cylinder Bore Sleeve Installation Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve (117), P/N 88984239, onto the cylinder block. Page 160 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 3487 Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 14721 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Page 12745 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 5839 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 14359 5. Pull the seat back cover down approximately 18 cm (7 in) from the top of the seat back, leaving the reinforcement bar exposed. 6. Install the hog rings that retain the seat back pad to the reinforcement bar. 7. Pull the seat cover over the seat back pad. 8. Press the seat cover hook and loop retaining strips together by firmly running your hand over the seat back cover. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the seat belt bezel to the top of the seat back with the mounting screw. Tighten Tighten the seat belt bezel screw to 3 N.m (26 lb in). Page 15505 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM/BCM Replacement - DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Page 2373 Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Page 401 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 10112 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 12516 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 3849 Electrical Symbols Part 8 Page 4048 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 3600 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ..................................................................... 48-54 psi KOEO Key On Engine Off Page 14841 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 11681 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 10039 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Body - Rattle Under Hood Hood Support Rod: Customer Interest Body - Rattle Under Hood Bulletin No.: 04-08-63-005 Date: June 15, 2004 TECHNICAL Subject: Rattle Noise Under Hood (Reposition Hood Prop Rod) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a slight buzz or rattle noise coming from under the hood. This noise could be mistaken for a unusual engine noise. Cause The hood prop rod may be making contact with the fan shroud. Correction Adjust the hood prop rod. 1. Support the hood. 2. Make sure the plastic prop rod pivot block is fully seated into the radiator support before making the adjustment. 3. Adjust the prop rod by bending the rod at the point of contact. Refer to the arrow in the illustration above. There should be approximately 10 mm (3/8 in) between the prop rod and the shroud. Warranty Information For vehicles repaired under warranty, use the table. Page 8814 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 3277 9. Remove the camshafts. 10. Using a suitable adapter, apply air pressure to the cylinder. 11. Install the J 44228 and compress the valve 12. Remove the valve keys. 13. Remove the J 44228. Page 9445 Parts Information Parts are expected to be available 8-22-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Capacity Specifications Coolant: Capacity Specifications Cooling System 13.9 qt (US) Page 4076 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1119 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 5729 Electrical Symbols Part 7 Page 7122 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Ensure that the vehicle is in the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the end of the range selector cable from the transmission range selector lever ball stud (6). 4. Remove the retainer (5) from the range selector cable. 5. Remove the range selector cable (4) from the bracket (1). 6. Remove the cable from the retainer (3) on the floor panel. If the vehicle is equipped with 4WD, remove the cable from the retainers located on the transfer case. 7. Push the cable grommet (2) up through the floor panel. 8. Lower the vehicle. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 5536 Page 10324 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6045 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Engine - Broken Bolt Extraction Information Crankshaft Main Bearing: Technical Service Bulletins Engine - Broken Bolt Extraction Information INFORMATION Bulletin No.: 05-06-01-026B Date: October 21, 2008 Subject: Information On Torque to Yield Bolt Breakage and Use of Bolt Extractor Tool Kit Part Number EN-47702 for Removing Broken Cylinder Head or Main Bearing Cap Bolts on Inline Truck Engines Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer 2004-2009 Chevrolet Colorado 2002-2009 GMC Envoy 2004-2009 GMC Canyon 2002-2004 Oldsmobile Bravada 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with 2.8L, 2.9L, 3.5L, 3.7L or 4.2L Vortec Inline Engine (VINs 8, 9, 6, E, S - RPOs LK5, LLV, L52, LLR, LL8) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-06-01-026A (Section 06 - Engine/Propulsion System). A Torque To Yield (TTY) bolt, like a cylinder head bolt or main bearing cap bolt, may break during repair procedures. Interaction between a TTY bolt and threads may cause the bolt to bind or break on removal. Prior to removing the cylinder head or main cap bolts, perform the following procedure: Using an appropriately sized punch and hammer, rap on the head of each bolt. The vibration produced by this procedure will assist in successful removal. If a head bolt or main bolt breaks during engine disassembly, a broken bolt extractor kit (EN-47702) has been released to assist in removal of the remaining bolt segment. Many times the remaining bolt segment will back out easily with a pick tool or a reverse twist drill bit. Bolt Replacement & Tightening Important: Never reuse TTY main bearing or cylinder head bolts. Always make sure that the engine block threaded holes are clean and do not place oil or threadlocker on the bolts. Utilize a thread chase tool followed by cleaning with dry compressed air to insure threads are clean and dry prior to installation of new TTY bolts. Bolts that creak and snap while tightening will fail due to excessive torque caused by threads contaminated with debris, antifreeze or oil. Trace amounts of oil or antifreeze will cause this condition. In extreme cases the threads may need additional cleaning with a non-residue cleaner like a brake clean product followed by drying with clean & dry compressed air. Page 6510 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 9463 C304 Part 1 Heater - Insufficient Heat To Driver's Feet Air Duct: Customer Interest Heater - Insufficient Heat To Driver's Feet File In Section: 01 - HVAC Bulletin No.: 01-01-38-014 Date: January, 2002 TECHNICAL Subject: Insufficient Heat To Driver's Feet (Install New Floor Air Outlet Duct) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the heater does not warm the driver's feet. Cause The left floor air outlet duct may not direct enough warm air to the area around the driver's feet. Correction Install a new left-hand floor air outlet duct, P/N 15093513 (RPO CJ3 manual HVAC controls) or P/N 15093514 (RPO CJ2 automatic HVAC controls). The new duct has an additional outlet and revised outlet shapes. Refer to the Air Outlet Duct Replacement - Floor LH procedure in the Heating, Ventilation and Air Conditioning section of the Service Manual (SI2000 Document ID # 744975). Parts Information Parts are expected to be available 1-7-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Page 7779 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 4781 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 6685 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Page 9297 Electrical Symbols Part 7 HVAC Systems - Manual Control Assembly: Locations HVAC Systems - Manual Locations View - HVAC Systems - Manual Page 15362 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 8380 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 881 For vehicles repaired under warranty, use the table. Disclaimer Page 12877 Disclaimer Page 1161 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 15503 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10686 Air Duct: Service and Repair Air Distributor Duct Replacement REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the driver side air distributor duct screws. 3. Remove the air distributor duct (1) from the instrument panel. INSTALLATION PROCEDURE 1. Install the air distributor duct (1) to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws to the air distributor duct. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the IP assembly. Page 8065 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 12045 Electrical Symbols Part 6 Page 14285 Seat Adjuster Switch - Driver (W/Memory Seat) Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 14674 2. Remove the weatherstrip from the pinch flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure Page 2639 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 8208 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 12167 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 10745 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14937 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Audio/A/C - Settings Change While Driving Body Control Module: Customer Interest Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3875 Conversion - English/Metric Page 12455 Parts Information Page 3276 Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 38820 Valve Stem Seal Remover and Installer - J 44222 Camshaft Sprocket Holding Tool - J 44228 Valve Spring Compressor Removal Procedure Important: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components, as previously installed. 1. Remove the cam cover. 2. Remove the spark plugs. 3. Remove the exhaust and the intake sprocket bolts. 4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components. 5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension. 6. Carefully move the sprockets with the timing chain, off of the camshafts. 7. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 8. Remove the camshaft caps. Page 12235 Page 898 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 6265 3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic. 4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3). 5. Install the washer and snap ring retaining the motor/encoder rotary position sensor. 6. Install the motor/encoder gasket (1). Locations Locations View Page 7385 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 5157 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4570 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12192 Tape Player: Service and Repair Personal Message Player/Recorder Replacement REMOVAL PROCEDURE 1. Remove the overhead console. 2. Disconnect the electrical connector from the personal message recorder (1). 3. Remove the personal message recorder retaining screws. 4. Remove the personal message recorder from the overhead console. 5. Remove the button assembly from the overhead console. INSTALLATION PROCEDURE 1. Install the button assembly to the overhead console. 2. Install the personal message recorder to the overhead console ensuring the light indicator is fully recessed into the opening (1). NOTE: Refer to Fastener Notice in Service Precautions. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 2635 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 1606 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10284 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the steering gear crossmember mounting bolts. Tighten the steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the lower control arm to frame mounting bolts. Tighten the lower control arm to frame mounting bolts to 265 N.m (196 lb ft). 4. Install the engine shield. 5. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 6. Lower the vehicle. Page 15396 Electrical Symbols Part 5 Page 3897 Electrical Symbols Part 2 Page 15122 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 380 Electrical Symbols Part 4 Page 11946 Page 1889 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 2502 Fluid - Transfer Case: Service and Repair Transfer Case Fluid Replacement (Trailblazer Ext, Envoy XL) Transfer Case Fluid Replacement (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the drain plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drain plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 3. Fill the transfer case with the proper fluid. Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, the SIR sensor must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 1527 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 3700 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5994 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Lift Gate Trim Panel Replacement Trunk / Liftgate Interior Trim Panel: Service and Repair Lift Gate Trim Panel Replacement TRIM PANEL REPLACEMENT - LIFT GATE REMOVAL PROCEDURE 1. Open the liftgate window. 2. Remove the push-pin retainer from the trim panel. 3. Close the liftgate window. 4. Open the liftgate. 5. Remove the screw that retains the pullstrap to the liftgate trim panel. 6. Remove the pullstrap from the liftgate trim panel. 7. Use a flat-bladed tool in order to carefully release the trim panel retainers. 8. Remove the trim panel from the liftgate. INSTALLATION PROCEDURE Page 34 Page 3745 12. Install the oil level indicator tube. 13. Move the transmission filler tube back onto the A.I.R. adapter block stud and secure the tube with a nut. ^ Tighten the transmission filler tube bracket nut to 10 Nm (89 inch lbs.). 14. Install the air cleaner resonator outlet duct. Page 11041 Refrigerant: Service Precautions CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 165 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 4066 Electrical Symbols Part 7 Page 14667 Rear Door Weatherstrip: Service and Repair Rear Door Upper REMOVAL PROCEDURE 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. INSTALLATION PROCEDURE 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Page 7264 Left Side Control Valve Body Assembly Page 12866 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7124 2. Install the range selector cable (2) to the floor shift control assembly. 3. Install the end of the range selector cable (1) to floor control ball stud. 4. Install the driver's side front mat and carpet. 5. Install the console. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Install the cable to the retainer (3) on the floor panel. If the vehicle is equipped with 4WD, install the cable to the retainers located on the transfer case. 8. Install the range selector cable (4) to the bracket (1). 9. Install the retainer (5) to the range selector cable. 10. Install the end of the range selector cable to the transmission range selector lever ball stud (6). 11. Adjust the range selector cable. 12. Lower the vehicle and check for proper operation. Page 9144 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 3069 2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil level indicator tube stud. ^ Tighten the oil level indicator tube stud to 10 Nm (89 inch lbs.). 4. Install the A/C line bracket to oil level indicator tube and secure with the nut. ^ Tighten the A/C line bracket nut to 7 Nm (6 inch lbs.). 5. Connect the 02 sensor electrical connector. 6. Install the oil level indicator into the tube. Page 14737 Electrical Symbols Part 6 Page 9801 C314 C315 Part 1 Page 15774 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 405 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5823 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4610 Electrical Symbols Part 4 Page 5228 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 471 Memory Seat Module - Passenger C4 Page 12740 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 15400 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 8640 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 263 Page 3810 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15137 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 1453 Electrical Symbols Part 7 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 15638 Tighten the two screws to 2.5 N.m (22 lb in). Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent, to the underside of the CHMSL applique. Remove the old adhesive from the liftgate glass. The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. DO NOT use commercial glass or surface cleaners. These may contain petroleum. The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply adhesive promoter, P/N 12378555 (in Canada, use P/N 88901239), to the liftgate glass surface, completely wetting the applique application area. Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the liftgate glass. Do not wipe the glass dry. Allow the liftgate glass to air dry completely. The applique must be installed within 30 minutes following the use of the promoter. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. Attach the CHMSL wire to the connector and install the grommet. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. Remove the protective liner from the tape on the applique. Attach the locating hooks on the applique to the hinge pins. Apply the applique to the liftgate glass. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure insuring complete contact of the adhesive strip to the glass. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. Clean the liftgate glass and applique area. Page 9119 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 4182 Electrical Symbols Part 8 Page 5568 Electrical Symbols Part 2 Page 15309 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 14466 3. Remove the seat riser latch assembly (1) from the seat latch rod (2). 4. Remove the retainer nut (2) from each end of the seat latch rod (1). 5. Remove the seat latch rod. INSTALLATION PROCEDURE Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 5636 12. Disconnect the chassis fuel return pipe (1) from the fuel tank fuel return pipe. 13. Disconnect the chassis fuel feed pipe (3) from the fuel filter. 14. Remove the fuel bundle. IMPORTANT: Note the position of the fuel bundle clips before disassembly. 15. Remove the fuel bundle retaining clips. 16. Remove the fuel feed (1), fuel return (2), or EVAP purge (3) pipe to be replaced. INSTALLATION PROCEDURE Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12001 1. Install the video assembly to the vehicle. 2. Lift the and adjust the video assembly in order to install the T-hook (1) to the video player bracket. Ensure the T-hook is fully seated to the bracket. 3. Support the front of the video assembly and connect the video assembly electrical connector (2). 4. Align the retaining fastener (3) to the corresponding hole in the video player bracket. 5. Raise the front of the video assembly to install the retaining fastener (3). 6. Partially install the rear retaining bolts. 7. Adjust the video display screen to a full open position. 8. Partially install the front retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. 9. Fully seat the retaining bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 10. Verify the video display for proper operation. 11. Close the video display screen. 12. Install the bolt cover bezel. Page 10734 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: Customer Interest A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 10735 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 813 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12900 Front Door Hinge: Service and Repair Door Side Hinge Door Side Hinge REMOVAL PROCEDURE IMPORTANT: The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the four weld locations. IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during drilling. Page 4986 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4031 Crankshaft Position (CKP) Sensor Page 7355 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Page 1181 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. Page 14600 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 7370 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 7787 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Specifications Engine Oil Pressure: Specifications Oil Pressure (At the sending unit) Warm - Minimum 12 psi - 1200 RPM Page 3592 Electrical Symbols Part 4 Page 9414 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 1451 Electrical Symbols Part 5 Page 7240 Page 2423 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft) 4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 5. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 6. Install the air cleaner. Audio/A/C - Settings Change While Driving Body Control Module: All Technical Service Bulletins Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11644 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Page 5256 Electrical Symbols Part 4 Page 4958 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10277 8. Remove the rear axle upper control arm to frame mounting bolt. 9. Remove the rear axle upper control arm. Installation Procedure 1. Install the rear axle upper control arm. 2. Install the rear axle upper control arm to frame mounting bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle upper control arm to axle mounting nut and bolt. Tighten the rear axle upper control arm mounting bolts to 130.5 Nm (96 ft. lbs.). 4. If equipped with air suspension, connect the air suspension leveling sensor link to the rear axle upper control arm. Page 15010 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Page 1408 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8468 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 13625 Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Rear (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Page 14747 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 8476 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 2734 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 10979 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. A/C - Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5099 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5747 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 7856 Page 14374 5. Unhook the J-strip (1) from the bottom of the seat back cover. 6. Remove the hog rings (2) from the seat back cover flaps. 7. Pull the seat back cover up by releasing the hook and loop fastener strips (2). 8. Remove the hog rings (1) securing the cover to the pad. 9. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 10. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. Page 13711 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 971 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ..................................................................... 48-54 psi KOEO Key On Engine Off Page 7181 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 14408 5. Fold the carpet back in order to release the J-strips that retain the cover to the seat pan. 6. Starting at either forward corner, compress the foam and partially remove the seat cover assembly from the seat pan. IMPORTANT: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 7. Remove the cover from the cushion by separating the retaining strips. 8. Separate and remove the cushion and cover assembly from the seat pan. 9. Release the reinforcement bar from the hog-rings. 10. Remove the cover from the cushion. INSTALLATION PROCEDURE 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. Page 3857 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 15517 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5105 Equivalents - Decimal And Metric Part 1 Page 10855 HVAC Control Module - Auxiliary (Body Type VIN 3) Oil Pressure Diagnosis Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following can cause low or no oil pressure: Low oil level-fill to the full mark on the oil level indicator. - Slow idle speed - Incorrect or malfunctioning oil pressure switch- replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gage- replace the oil pressure gage. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if it is diluted. - The oil pump is worn or dirty-clean or replace the oil pump. - The oil filter is plugged-replace the oil filter. - The oil pickup screen is loose or plugged- replace the oil pickup screen. - A hole in the oil pickup tube-replace the oil pickup tube. - Excessive bearing clearance-replace the bearings. - Cracked, porous, or plugged oil galleries-repair or replace the engine block. - The gallery plugs are missing or improperly installed-install or repair as necessary. - The pressure regulator valve is stuck. Check the pressure regulator valve for sticking in the bore. - Check the bore for scoring and burrs. - The camshaft is worn or poorly machined- replace the camshaft. - Worn valve guides-repair as needed. Page 111 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Recall - Windshield Wiper Defect Technical Service Bulletin # 04005 Date: 040701 Recall - Windshield Wiper Defect File In Section: Product Recalls Bulletin No.: 04005 Date: July, 2004 PRODUCT SAFETY RECALL SUBJECT: WINDSHIELD WIPER OPERATION MODELS: 2002-2003 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2002-2003 GMC ENVOY, ENVOY XL 2002-2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles. Under certain conditions, water may seep into the windshield wiper module. If this were to happen, it could result in windshield wipers that will not turn on, cease operation while driving, fail to turn off, turn on by themselves, and/or continuous windshield washer pump operation. Improper operation of the windshield wiper system in a severe weather situation could reduce the driver's visibility, resulting in a possible vehicle crash without prior warning. CORRECTION Dealers are to inspect and seal the windshield wiper motor. In some cases, the windshield wiper module may require replacement. VEHICLES INVOLVED Involved are certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. Page 12366 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 5934 Electrical Symbols Part 8 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 7123 9. Remove the console. 10. Remove the driver's side front mat and carpet. 11. Remove the end of the range selector cable (1) from the floor control ball stud. 12. Remove the range selector cable (2) from the floor shift control assembly. 13. Remove the tape and grommet on the shift cable from the floor panel. 14. Remove the range selector cable (3) from the vehicle. Installation Procedure 1. Push the cable down through the floor panel and install the grommet (2). Page 5078 Electrical Symbols Part 4 A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 1000 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Page 14800 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 412 Driver Door Module (DDM) C2 Page 6167 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-965 Audio System - Whine/Buzz Noise on Acceleration Technical Service Bulletin # 02-08-44-016A Date: 021201 Audio System - Whine/Buzz Noise on Acceleration File In Section: 08 - Body and Accessories Bulletin No.: 02-08-44-016A Date: December, 2002 TECHNICAL Subject: Whine, Buzz, Generator Whine, Whine Type Noise Heard on Acceleration (Repair Vehicle Sound System Wiring) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to December, 2001 This bulletin is being revised to change the model year. Please discard Corporate Bulletin Number 02-08-44-016 (Section 08 - Body and Accessories). Condition Some customers may comment on a buzzing or generator whine-type noise that emanates from the vehicle speakers with the radio on or off and when the headlights are on. This sound may be altered by changing the IP backlighting intensity (Dimming Function). Or, a noise emanates from the All-Wheel Drive system (if equipped), of 1 to 2 seconds duration during initial acceleration, at 24 km/h (15 mph) or at 48 km/h (30 mph). The generator whine-type noise may be observed at any time, however it is more noticeable when the electrical load on the system is high. Cause The cause of this condition may be EMI interference that is being transmitted to the radio system speakers from within the body wiring harness. Correction To determine which parts to order, you will need to inspect the vehicle. There are four types of audio systems available and three specific service wiring harness assemblies. ^ Bose(R) Premium Sound System with Rear Audio Controls ^ Bose(R) Premium Sound System without Rear Audio Controls ^ Non-Bose(R) Sound System with Rear Audio Controls ^ Non-Bose(R) Sound System without Rear Audio Controls See the Parts Information below for applicable part numbers. Parts Information Paris are currently available from GMSPO. Warranty Information Body - Liftgate Glass Unlatches On Bumpy Roads Tailgate Latch: All Technical Service Bulletins Body - Liftgate Glass Unlatches On Bumpy Roads Bulletin No.: 04-08-66-004A Date: June 22, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Liftgate Glass Unlatches on Rough/Bumpy Road Surfaces (Replace Liftgate Window Latch) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to provide the correction and warranty information, which is now available for Advanced Service Bulletin Number 04-08-66-004. Please discard Corporate Bulletin Number 04-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear liftgate window unlatches when driving on rough/bumpy road surfaces. This condition may be very difficult to duplicate. Cause The liftgate window latch may be the cause of this condition. Correction Replace the liftgate window latch. Refer to the Liftgate Window Latch Replacement procedure in the Body Rear End sub-section of the Service Manual. Part Information Parts are expected to be available from GMSPO on June 25, 2004. Warranty Information For vehicles repaired under warranty, use the table. Page 4689 Electrical Symbols Part 1 Page 4928 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 12394 For vehicles repaired under warranty use, the table. Disclaimer Page 4227 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 3529 10. Unclip the fan shroud from the radiator at the side panels (1). 11. Tilt the radiator and the condenser forward. 12. Lift the fan and the shroud up and out towards the engine to release the fan from the radiator to clear the radiator inlet. Installation Procedure 1. Install the fan and the shroud onto the lip of the radiator bottom. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts into the upper fan shroud and tighten. ^ Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Connect the electrical connector. 4. Clip the fan shroud to the radiator at the side panels (1). Page 1330 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Assembly to Case Bolt ......................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Page 5119 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 15410 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 9846 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 15286 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Instruments - Erratic Speedometer Operation Ground Strap: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 14033 For vehicles repaired under warranty, use the table. Disclaimer Page 1109 Seat Adjuster Switch - Driver (W/Memory Seat) Page 12511 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 9416 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Service and Repair Front Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the pushpins from the wheelhouse liner. 2. Remove the bolt that retains the wheelhouse liner to the rocker molding. 3. Remove the wheelhouse liner from the vehicle. Installation Procedure 1. Install the wheelhouse liner to the vehicle. 2. Install the pushpins that retain the wheelhouse liner to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the wheelhouse liner to the rocker molding. Tighten the bolt to 10 N.m (89 lb in). Page 13798 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Audio/A/C - Settings Change While Driving Body Control Module: All Technical Service Bulletins Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12310 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 5230 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15808 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 6387 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 14347 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 15498 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5874 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 621 Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T79) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the fog lamp relay from the bussed electrical center. INSTALLATION PROCEDURE Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 13889 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located inside the instrument panel I/P compartment. The label is used to help identify the vehicle original parts and options. Page 7802 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 15363 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5980 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7757 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 888 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15606 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 10773 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the rear HVAC module assembly. 2. Disconnect the electrical connector from the blower motor control processor-auxiliary (3). 3. Remove the screws from the blower motor control processor-auxiliary (3). 4. Remove the blower motor control processor-auxiliary (3). 5. Remove the thermal gasket from the evaporator core-auxiliary surface. INSTALLATION PROCEDURE 1. Install the thermal gasket to the blower motor control processor-auxiliary. 2. Install the blower motor control processor-auxiliary (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the blower motor control processor-auxiliary (3). Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the electrical connector to the blower motor control processor-auxiliary (3). 5. Install the HVAC module-auxiliary. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 735 Electrical Symbols Part 3 Page 15786 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 2631 Fuse Block - Underhood C6 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 5008 control module damage may occur. - If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. AFTER PROGRAMMING A CONTROL MODULE The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: Fuel trim correction - Idle Air Control (IAC) learned position - Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: The crankshaft variation learn procedure - The engine oil life reset procedure - The idle learn procedure - The inspection/maintenance complete system set procedure - The vehicle theft deterrent password learn procedure - The Throttle Position (TP) sensor learn procedure A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 4340 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 6734 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3125 Electrical Symbols Part 4 Page 12251 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 886 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 10650 1. Remove the IP carrier.See: Instrument Panel, Gauges and Warning Indicators 2. Remove the air temperature actuator-right retaining screws. 3. Disconnect the air temperature actuator-right electrical connector. 4. Remove the air temperature actuator-right. INSTALLATION PROCEDURE 1. Install the air temperature actuator-right. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the air temperature actuator-right retaining screws. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 3. Install the air temperature actuator-right electrical connector. 4. Install the I/P carrier.See: Instrument Panel, Gauges and Warning Indicators 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Defroster Actuator REMOVAL PROCEDURE Page 11087 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 13757 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Body - Revised Liftgate Lock Cylinder Replacement Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Body - Revised Liftgate Lock Cylinder Replacement Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X This bulletin is being issued to revise the Lock Cylinder Replacement - Liftgate procedure in the Body Rear End sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. Refer to Wiper Motor Replacement - Rear. 2. Remove the lock rod from the lock cylinder. Page 5165 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 12816 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 02-08-62-001 Date: 020801 Body - Front Fascia is Loose File In Section: 08 - Body and Accessories Bulletin No.: 02-08-62-001 Date: August, 2002 TECHNICAL Subject: Front Fascia Loose (Replace Front Fascia Pencil Braces) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22375120 Condition Some customers may comment that the front fascia on the vehicle appears to be loose. This condition may be noticed while the customer is washing the vehicle. Correction Replace the front fascia pencil braces using the following service procedure. Page 15588 Electrical Symbols Part 4 Page 9048 Parking Brake Lever: Service and Repair Park Brake Lever Assembly Replacement Removal Procedure 1. Remove the floor console. 2. Disable the Park Brake Automatic Adjuster. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Disconnect the park brake cables from the equalizer. 5. Lower the vehicle. 6. Disconnect the electrical connector from the park brake warning lamp switch. 7. Remove the remaining park brake lever retaining nut. 8. Remove the park brake lever assembly from the vehicle. Installation Procedure Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 7598 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3868 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1806 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3005 13. Install the camshaft cover. Page 15419 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 9567 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 2257 Wiper Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel (IP) accessory trim plate. 2. Disconnect the electrical connector from the wiper washer switch. 3. Release the wiper washer switch locking tabs. 4. Remove the switch from the trim plate. INSTALLATION PROCEDURE 1. Position the switch to the trim plate. 2. Connect the electrical connector to the wiper washer switch. 3. Install the switch to the instrument panel trim plate, ensuring that the locking tabs are properly seated. 4. Install the instrument panel (IP) accessory trim plate. Page 10992 19. Lower the vehicle. 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Cooling System. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Cooling System. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Obtain a new A/C or heater line for sectioning. IMPORTANT: Stagger the splices if repairing more than one line. 5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. IMPORTANT: The length of the replacement line must be the same as the line being replaced. 8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 11. Use the LOK prep sealant in order to prep the line ends. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J 41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Cooling System. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Page 3068 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the A/C line bracket nut. 2. Remove the A/C line bracket from the oil level indicator tube stud. 3. Disconnect the 02 sensor electrical connector from the oil level indicator bracket. 4. Remove the oil level indicator tube stud. 5. Pull the indicator out of the tube. 6. Pull the tube out of the block. Installation Procedure 1. Install the oil level indicator tube into the engine block. Page 12675 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 2343 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 9608 Disclaimer Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 11865 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 15618 Conversion - English/Metric Page 2624 Fuse Block - Rear C4 Page 13704 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Symptom Related Diagnostic Procedures Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. Refer to Checking Aftermarket Accessories in Diagnostic Aids. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. See: Garage Door Opener Inoperative Garage Door Opener Inoperative Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 1552 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 933 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 4711 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 14653 Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Front Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten the retaining bolts to 10 N.m (88 lb in). 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Page 3512 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Page 13879 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Page 15334 Speedometer Head: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Front Brake Pads Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove the brake fluid with appropriate tool to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 1318 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 15784 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4411 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 3242 Equivalents - Decimal And Metric Part 1 Page 1439 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 10510 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 2267 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 3134 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 5081 Electrical Symbols Part 7 Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 14425 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 5. Install the seat harness to the seat pan. 6. Install the SIR harness (2) to the seat clips (1, 4). 7. Connect the gray lumbar electrical connector (5), if equipped. 8. Connect the black electrical connector (3) to the seat belt buckle. 9. Connect the black electrical connector (6) to the seat back harness. 10. Install the 3 seat switch bezel mounting screws. Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Removal Procedure 1. Remove the trim panel from the power seat by performing the following: 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 3 trim panel retaining screws. 2. Remove the trim panel from the manual seat by performing the following steps: 1. Remove the lumbar support knob. 2. Remove the seat back recliner handle. 3. Remove the screws from the trim panel. 3. Remove the trim panel from the seat assembly. Installation Procedure Page 9472 C314 C315 Part 1 Page 4054 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Body - Rear License Plate Pocket Gasket is Loose License Plate Bracket: All Technical Service Bulletins Body - Rear License Plate Pocket Gasket is Loose Bulletin No.: 04-08-66-001E Date: December 13, 2007 TECHNICAL Subject: Rear License Plate Pocket Perimeter Gasket Loose/Out of Position Or Excessive Amount Of Adhesive (Install New Gasket Using Updated Retainer Tightening Sequence) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and change the part numbers. Please discard Corporate Bulletin Number 04-08-66-001D (Section 08 - Body & Accessories). Condition Some customers may comment that the insulating perimeter seal or gasket on the backside edge of the license plate housing/pocket appears to be shrinking or becomes pulled away from the edge of the license plate housing/pocket. Some customers may also comment about excessive amounts of adhesive oozing from the gasket. Cause This condition may be caused by changes in temperature, which may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing gasket seal may be caught and pulled under the housing/pocket. Correction A new gasket without the adhesive has been released for service. Technicians are to replace the rear license plate pocket perimeter gasket using the following procedure: Excessive amounts of adhesive, which may have oozed from the gasket, may be cleaned using GM Tar and Road Oil Remover, P/N 1050172 (in Canada, P/N 992856), or the equivalent. Remove the rear license plate pocket assembly. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Remove the rear license plate pocket perimeter gasket. Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling-Colder plug ^ Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 12505 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 10110 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Service and Repair Parking Lamp Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the park lamp relay (1) from the bussed electrical center. INSTALLATION PROCEDURE Page 12858 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5857 Electrical Symbols Part 4 Page 9241 Alternator: Description and Operation GENERATOR The AD-244 generator is non-repairable. They are electrically similar to earlier models. The generator(s) feature the following major components: - The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for Air-cooled Dual internal fan; the 2 is an electrical design designator; the 44 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generator is rated at 150 amperes. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Page 6435 Page 14778 Electrical Symbols Part 7 Page 11083 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch - HVAC Systems Manual A/C Low Pressure Switch - HVAC Systems Automatic Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid (GM Part No. 12377967 or equivalent DOT-3 brake fluid). Page 14406 9. Connect the seat cushion heater electrical connector. 10. Install the seat electrical harness to the seat pan. 11. Install the SIR electrical harness (2) to the seat pan. 12. Install the front/rear J strips (2,4). 13. Install the side J strips (1,3). 14. Install the seat pan to the seat adjuster frame. Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: All Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 13194 Liftgate Module (LGM) C2 (Except XUV) Specifications Valve Spring: Specifications Valve Spring Valve Springs Load (Closed) 47.5-52.5 lb @ 1.701 inch Valve Springs Load (Open) 130-142 lb @ 1.260 inch Page 10917 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1148 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 8648 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 15730 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5789 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5999 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Exhaust Camshaft Position Actuator Replacement Camshaft: Service and Repair Exhaust Camshaft Position Actuator Replacement Camshaft Position Exhaust Actuator Replacement Tools Required J 36660-A Torque Angle Meter - J 44217 Timing Chain Retention Tool Removal Procedure 1. Remove the camshaft cover. Refer to Camshaft Cover Replacement. 2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with the cylinder head to cam cover mating surface. 3. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link across from it. Page 10658 Air Door Actuator / Motor: Service and Repair Manual Control Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the air temperature actuator. 3. Remove the retaining screws from the air temperature actuator. 4. Remove the air temperature actuator (1) from the rear HVAC module. INSTALLATION PROCEDURE 1. Install the air temperature actuator (2) to the rear HVAC module. 2. Install the retaining screws to the air temperature actuator. 3. Connect the electrical connector to the air temperature actuator. 4. Recalibrate the air temperature actuator. Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). 5. Install the right rear quarter trim panel. Left REMOVAL PROCEDURE Page 5570 Electrical Symbols Part 4 Body - Rear License Plate Pocket Gasket is Loose License Plate Bracket: Customer Interest Body - Rear License Plate Pocket Gasket is Loose Bulletin No.: 04-08-66-001E Date: December 13, 2007 TECHNICAL Subject: Rear License Plate Pocket Perimeter Gasket Loose/Out of Position Or Excessive Amount Of Adhesive (Install New Gasket Using Updated Retainer Tightening Sequence) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and change the part numbers. Please discard Corporate Bulletin Number 04-08-66-001D (Section 08 - Body & Accessories). Condition Some customers may comment that the insulating perimeter seal or gasket on the backside edge of the license plate housing/pocket appears to be shrinking or becomes pulled away from the edge of the license plate housing/pocket. Some customers may also comment about excessive amounts of adhesive oozing from the gasket. Cause This condition may be caused by changes in temperature, which may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing gasket seal may be caught and pulled under the housing/pocket. Correction A new gasket without the adhesive has been released for service. Technicians are to replace the rear license plate pocket perimeter gasket using the following procedure: Excessive amounts of adhesive, which may have oozed from the gasket, may be cleaned using GM Tar and Road Oil Remover, P/N 1050172 (in Canada, P/N 992856), or the equivalent. Remove the rear license plate pocket assembly. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Remove the rear license plate pocket perimeter gasket. Page 10660 1. Remove the I/P carrier. 2. Remove the right side air temperature actuator retaining screws. 3. Disconnect the right side air temperature actuator electrical connector. 4. Remove the right side air temperature actuator. INSTALLATION PROCEDURE 1. Install the right side air temperature actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the right side air temperature actuator retaining screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the right side air temperature actuator electrical connector. 4. Install the I/P carrier. 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Defroster Actuator REMOVAL PROCEDURE Page 2594 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 10267 7. Pivot the lower control arm outward and downward for access to the lower control arm bracket. 8. Remove the lower control arm bracket mounting bolts from the frame. 9. Remove the lower control arm bracket from the vehicle. Installation Procedure 1. Install the lower control arm bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower control arm bracket mounting bolts to the frame. ^ Tighten the front lower control arm bracket mounting bolt to 260 Nm (192 ft. lbs.). ^ Tighten the rear lower control arm bracket mounting bolts to 240 Nm (177 ft. lbs.). 3. Install the lower control arm to the lower control arm bracket. 4. Install the lower control arm to lower control arm bracket mounting bolts. Page 11988 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 11284 Side Air Bag: Service and Repair Inflator Module Handling, Shipping, and Scrapping Do NOT deploy the inflator module in the following situations: ^ After replacement of an inflator module under warranty-The inflator module may need to be returned undeployed to the manufacturer. ^ If the vehicle is the subject of a product liability report (1241) related to the SIR or seat belt system-When a vehicle is the subject of a product liability report, do not alter the SIR or seat belt system in any manner. ^ If the vehicle is involved in a campaign affecting the inflator modules-Follow the instructions in the campaign service bulletin for proper SIR handling procedures. Deployment Procedures: The inflator module can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review each procedure in order to determine which will work best in a given situation. Dual Stage Inflator Module: Dual stage inflator modules have 2 deployment stages. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. Therefore, a deployed inflator module must still be treated as an active inflator module. If disposal of a deployed or undeployed dual stage module is required, both deployment loops must be energized to deploy the inflator module. Scrapping Procedure: During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a undeployed inflator module. Do not dispose a undeployed inflator module through normal disposal channels until the inflator module has been deployed. If scrapping a deployed dual stage inflator module, both stages must be energized. The following information covers the proper procedures for the disposing of a undeployed inflator module. Undeployed Inflator Module: Take special care when handling or storing a undeployed or live inflator module. An inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment. Page 13561 For vehicles repaired under warranty, use the table. Disclaimer Page 5033 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 13883 Disclaimer Page 15602 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 797 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 8799 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Intake Air Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Diagrams Intake Air Temperature Sensor Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Page 3050 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the right frame engine mount bracket bolts. if removed. ^ Tighten the mount bracket bolts to 110 Nm (81 ft. lbs.). 3. Note: Graphic shows left, right is similar. Install the right engine mount bracket and secure with the bolts (1). ^ Tighten the engine mount bracket bolts to 50 Nm (37 ft. lbs.). 4. Install the right engine mount. 5. Lower the engine onto the engine mounts. 6. Install the right and the left upper engine mount nuts. Page 13829 11. Install the three torque head screws. Tighten Tighten the torque head screws to 10 Nm (89 lb-in.). 12. Install the wire harness if equipped with heated mirror and turn signal. 13. Line up the mirror back with the actuator. Press firmly in the center of the glass using the palm of your hand. The mirror and backing plate will snap onto the actuator. 14. Make sure the mirror is locked in by lightly pulling on the mirror glass. Check the operation of the mirror and clean the glass. Parts Information Parts are expected to be available from GMSPO on September 24, 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11979 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 5872 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12042 Electrical Symbols Part 3 Page 8109 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 7393 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover and the gasket. 7. Install the tire and wheel assembly. 8. Fill the rear axle with axle lubricant. Use the proper fluid. 9. Lower the vehicle. Page 14261 Power Seat Motor: Service and Repair Seat Adjuster Mechanism Replacement - Power Removal Procedure 1. Remove the front bucket seat assembly from the vehicle. 2. Remove the seat cushion trim panel. 3. Remove the seat belt buckle nut. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1,4), and remove the SIR harness from the seat. 8. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 9. Remove the seat back. Installation Procedure Locations Locations View Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 9744 For vehicles repaired under warranty, use the table. Disclaimer Page 9479 C201 Part 2 Page 12056 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3246 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 4608 Electrical Symbols Part 2 Page 118 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 11816 Page 792 Electrical Symbols Part 6 Page 13492 21. Install the rear side door sill plates. 22. Install the second row seats. 23. Install the third row seats. 24. Install the luggage/cargo shade assembly, if equipped. 25. Install the cargo net, if equipped. 26. Install the front seats. Carpet Replacement - Rear (TrailBlazer, Envoy, Bravada) Carpet Replacement - Rear (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the front seats. 2. Remove the rear seat cushions. 3. Remove the communication interface module. 4. Remove the navigation control processor bracket. 5. Remove the seat back, left and right side. 6. Remove the front bucket seats. 7. Remove the front door sill plates. 8. Remove the rear door sill plates. 9. Remove the lift gate door sill plate. 10. Remove the center pillar trim panels. 11. Remove the lower rear quarter trim panels. 12. Remove the tool kit carrier. 13. Remove the bussed electrical center junction block from the bussed electrical center base, and the bussed electrical center base from the floor panel studs. 14. Remove the child restraint tether anchors. 15. Remove the bussed electrical center base and communication interface module electrical connectors through the pass through holes in the carpet. 16. Remove the floor console to the floor console carrier. 17. Remove the four nuts retaining the rear of the floor console bracket to the floor weld studs. 18. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 19. Remove the carpet from the vehicle. Installation Procedure Page 5702 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3615 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14624 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Page 14754 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5859 Electrical Symbols Part 6 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15366 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14874 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 7883 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Audio System - Clearing `CLN' Message From Display Tape Player: Technical Service Bulletins Audio System - Clearing `CLN' Message From Display File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-006A Date: June, 2001 INFORMATION Subject: Cleaning the Cassette Tape Player and Clearing the CLN Message from the Radio Display Models: 1996-2002 Chevrolet and GMC Truck Models With Remote Cassette Tape Player (RP0 UP0) This bulletin is being revised to include additional model years and models, parts information, and to provide a procedure for cleaning the cassette tape player and resetting the CLN indicator on the radio display. Please discard Corporate Bulletin Number 01-08-44-006 (Section 08 - Body and Accessories). When the CLN message appears on the audio system, it indicates that the cassette tape player requires cleaning. Customers should follow the listed instructions. The recommended cleaning method for the remote cassette player is to use a scrubbing action, non-abrasive cleaning cassette, GM P/N 12344789. The cleaning cassette scrubs the tape head as the hubs of the cleaner cassette turn. Use the following procedure to clean the remote cassette player and reset the CLN indicator on the radio. 1. With the radio ON, insert the recommended cleaning cassette. 2. After a few seconds, the cleaning cassette may eject because it may appear to the player as a cassette with a broken tape. If ejection occurs, reinsert the cleaning cassette. Continue this process three or four times until the cleaning cassette is engaged for the time recommended by the cleaning cassette instructions. 3. Eject the cleaning cassette if the cassette does not eject on its own. 4. Press and hold the RECALL button on the radio until CLN appears on the radio display. While still pressing the radio RECALL button, press EJECT on the remote player. Release both buttons when the radio display indicates that the CLN indicator timer has been reset. Parts Information Parts are currently available from GMSPO. DISCLAIMER Page 4068 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 2013 Page 11806 Circuit/System Testing Component Testing Page 5422 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 8104 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 5718 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 11387 Disclaimer Tools - Flywheel Holding Tool, Modification Flex Plate: Technical Service Bulletins Tools - Flywheel Holding Tool, Modification File In Section: 06 Engine/Propulsion System Bulletin No.: 01-06-01-017 Date: June, 2001 INFORMATION Subject: Flywheel Holding Tool J 44226-3A Modification or Replacement Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada With 4.2L Engine (VIN S - RPO LL8) All Chevrolet, GMC (light duty only) and Oldsmobile dealerships received tool J 44226-3A as part of the essential tool package. This tool may need modification to the welded area between the socket portion of the tool and the flat bar. Excessive weld in this area may cause the tool to not fully engage the bolt on the flywheel. If the tool does not fully engage the bolt, it could slip off during use, causing improper torque. Recommended Action Inspect tool J 44226-3A in the area shown. Remove excessive weld using a grinder. If a grinder is not available, or you cannot adequately remove the excess weld, call Kent-Moore Tools at 1-800-GM TOOLS for a free replacement. Disclaimer Page 10166 12. Disconnect the lower intermediate shaft boot from the power steering gear and remove the intermediate shaft boot from the vehicle. Important: Note the relationship of the intermediate shaft to the power steering gear and the intermediate shaft to the steering column in order to ensure proper installation. 13. Remove the lower intermediate shaft to the power steering gear input shaft pinch bolt. 14. Disconnect the lower intermediate shaft from the power steering gear. 15. Remove the lower intermediate shaft from the vehicle. 16. Replace the lower intermediate shaft, P/N 15155707. Parts Information Warranty Information Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. Page 3232 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 11952 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 8909 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Page 15371 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 1124 Heated Seat Element - Front Passenger Cushion Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 248 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 5097 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 3929 Conversion - English/Metric Page 14939 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 15713 Electrical Symbols Part 8 Page 7575 For vehicles repaired under warranty, use the table. Disclaimer Page 2753 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Bracket Replacement - Console Floor Console: Service and Repair Bracket Replacement - Console Floor Bracket Replacement - Console Floor Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the floor shift control knob. 3. Remove the center console. Console Replacement 4. Disconnect the automatic transmission range selector cable. 5. Disconnect the electrical connector from the automatic transmission shift interlock solenoid. 6. Disconnect the electrical connector from the park brake. 7. Remove the console bracket from the vehicle, by removing the retaining nuts (1) from the center instrument panel (IP) bracket. 8. Remove the forward retaining screw, if equipped. 9. Remove the remaining fasteners from the console bracket. 10. Remove the console bracket from the vehicle. 11. Remove the floor shift control. Installation Procedure 1. Install the floor shift control. 2. Install the console bracket to the vehicle. 3. Loosely install all the fasteners that retain the console bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the retaining nuts (1) to the center IP bracket. Tighten nuts to 10 N.m (88 lb in). 5. Install the remaining fasteners that retain the console bracket to the vehicle. Tighten the nuts to 25 N.m (18 lb ft). 6. Connect the electrical connector to the park brake. 7. Connect the electrical connector to the automatic transmission shift interlock solenoid. 8. Connect the automatic transmission range selector cable. 9. Install the center console. Console Replacement 10. Install the floor shift control knob. 11. Remove the wheel blocks from the vehicle. Page 15397 Electrical Symbols Part 6 Page 1837 For vehicles repaired under warranty, use the table. Disclaimer Page 8255 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Page 13483 size as the original Installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts retaining the rear of the floor console bracket to the floor weld studs. Tighten Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the child restraint tether anchors. 9. Install the bussed electrical center. 10. Install the tool kit carrier. 11. Install the 3 tool carrier nuts to the floor studs. Tighten Tighten the nuts to 7 N.m (62 lb in). 12. Install the lower rear quarter trim panels. 13. Install the center pillar trim panels. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1821 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 7900 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12901 5. Center punch each weld location (1). IMPORTANT: Drill through the hinge base only (1). Do not drill through the mating surface (2). Remove hinge tab (3) before drilling, if necessary. 6. At each punch location, drill a 3 mm (1/8 in.) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in.) rotabroach hole saw or equivalent (2). IMPORTANT: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 7445 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Page 7411 8. Place a brass drift against the cage (1). 9. Tap gently on the brass drift in order to tilt the cage (1). 10. Install the first ball (2) when the cage tilts. 11. Repeat previous step to reinstall all of the balls. 12. Pack the CV joint seal and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small swage clamp (2) onto the CV joint seal (1). 14. Place the large retaining clamp on the seal (1). 15. Position the small end of the CV joint seal (1) into the joint seal groove (3) on the halfshaft bar. 16. Position the outboard end of the halfshaft assembly (1) in J 41048. Page 8007 Page 9319 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 1426 Various symbols are used in order to describe different service operations. Page 11250 6. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. Tighten Tighten the front end discriminating sensor bolts to 8 N.m (71 lb in). 7. Position the headlamp wire harness (1) to the retaining clip. Page 15613 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement REMOVAL PROCEDURE 1. Remove the overhead console. 2. Disconnect the electrical connector from the garage door opener (3). 3. Remove the 3 retaining screws from the garage door opener. 4. Remove the garage door opener from the overhead console. 5. Remove the button assembly from the overhead console. INSTALLATION PROCEDURE 1. Install the button assembly to the overhead console. 2. Install the garage door opener to the overhead console. Fully recess the light indicator into the opening (1). NOTE: Refer to Fastener Notice in Service Precautions. Page 1678 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 5778 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 3225 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid (GM Part No. 12377967 or equivalent DOT-3 brake fluid). Page 2764 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 1019 20. Remove the backing material from the seal, align it over the wiper motor cover so that it completely covers the vent (2), and press it firmly into place as shown in the above illustration. Apply firm pressure across the entire surface of the seal and around all outside edges. Continue applying pressure a second time to the edges to assure full adhesion. 21. Position the wiper module to the vehicle and connect the electrical connector. 22. Install the wiper module in the plenum sheet metal. 23. Install the two 10 mm hex head bolts that attach the module to the plenum sheet metal. Tighten Tighten the bolts to 8 N.m (71 lb in). 24. Install the air inlet grille to the plenum sheet metal. 25. Install the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. Tighten Tighten the nuts to 4 N.m (35 lb in). 26. Install the antenna mast. Important If installing a NEW wiper module, you must verify that the new wiper motor and transmissions are in the PARK position before installing the wiper arms. 27. If installing a NEW wiper module, turn the ignition switch to the ON position, turn the wiper switch ON, and visually verify that the wiper transmissions operate. After visually verifying operation, turn the wiper switch to the OFF position and allow the wiper transmissions to stop moving before turning the ignition switch to the OFF position. The wiper motor will now be in the PARK position. 28. Using the marks or masking tape that were placed on the windshield, align and position the wiper arms on the wiper transmission shafts. 29. Install the nuts on the wiper transmission shafts. Tighten Tighten the nuts to 30 N.m (22 lb ft). 30. Install the covers on the wiper arm nuts. 31. Remove the marks or masking tape from the windshield. 32. Open the hood. 33. Install the three push-in retainers that attach the air inlet grille to the plenum sheet metal. 34. Close the hood. 35. Verify that all functions of the wiper system (low, high, delay, etc.) operate properly. Page 14366 8. Install the 3 push-pins at the bottom of the rear seat back. 9. Engage the hook and loop retaining strips at the bottom of the rear seat back. 10. Starting at either corner, engage the J strips at the bottom of the rear seat back. 11. Install the head restraints. 12. Install the seat belt bezel to the rear seat back with the plastic retainers (2). Page 2452 16. Connect the power steering hose assembly to the power steering gear. 17. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (9 ft. lbs.). 18. Remove the drain pan from under the vehicle. 19. Lower the vehicle. 20. Bleed the power steering system. Page 7664 Page 12170 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 13981 Front Passenger Door Module (FPDM) C2 Page 2246 Windshield Washer Fluid Level Switch Page 5710 Resonator: Service and Repair Air Cleaner Resonator Outlet Duct Replacement REMOVAL PROCEDURE 1. Remove the air cleaner element. 2. Disconnect the intake air temperature (IAT) sensor (3) electrical connector. 3. Loosen duct clamp (1) on the air cleaner side of the air cleaner outlet resonator (2). 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the air cleaner outlet duct onto the air cleaner outlet resonator (2). Tighten Tighten the duct clamp (1) to 4 N.m (35 lb in). 2. Reconnect the IAT electrical connector. 3. Install the air cleaner element. Page 8539 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 13414 Skid Plate: Service and Repair Engine Protection Shield Replacement Engine Protection Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. Installation Procedure 1. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 3. Lower the vehicle. Page 5678 Electrical Symbols Part 8 Page 6134 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 12673 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 3927 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3558 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 9548 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the park brake as firmly as possible, depress Auto Trans Shift Lock Control solenoid plunger and pull the shift lever to the L1 position. 15. Lift the console, disconnect the console wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (Trail Blazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (Except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward arid disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Brown/White wire. ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio in the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place it under the carpet to the area of the rear audio control and reposition the carpeting. Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 9624 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 3956 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 12976 6. Install the bolt that retains the motor to the door. Tighten Tighten bolts to 9 N.m (80 lb in). 7. Install the remaining bolts that retain the regulator assembly to the door. Tighten Tighten bolts to 10 N.m (88 lb in). 8. Connect the electrical connector to the regulator motor. 9. Install the side door window. 10. Install the water deflector. 11. Install the speaker. 12. Install the door trim panel. Page 5254 Electrical Symbols Part 2 Page 4132 Electrical Symbols Part 3 Page 15544 Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure 1. Open the rear liftgate. 2. Remove the two screws that attach both the left and right tail lamp assemblies and remove the lamps from the body. 3. Inspect the part number on both the left and right tail lamp circuit boards. Chevrolet -- New P/N 16532713 Chevrolet Export -- New P/N Page 12063 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 14405 1. Install the seat cushion to the seat pan. 2. Install the seat cover to the seat cushion. 3. Using a side to side motion, carefully pull the seat cushion cover onto the seat pan. 4. Install the seat module, if equipped. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the seat module retaining screw. Tighten Tighten the screw to 5 N.m (44 lb in). 6. Install the 11 hog rings to the top side of the cover and pad. 7. Install the 2 hog rings (1) to the bottom rear side of the cover and pad. 8. Press the seat cover hook and loop retaining strips together by running your hand firmly over the seat cover. Page 13716 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 7929 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4811 Malfunction Indicator Lamp (MIL) Inoperative - Steps 1-7 Page 5158 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 24 Disclaimer Page 3571 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE Page 2233 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 7989 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 11944 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 11398 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Center Rear Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Adjust the left rear seat back to a cargo position. 2. Adjust the seat filler panel on the bottom of the seat back in order to access the center rear seat back mounting nut. 3. Remove the rear seat back mounting nut. 4. Return the seat to an upright position. 5. Remove the clip(s) that retain the seat belt buckle anchor plate to the latch bracket. 6. Remove the seat belt buckle/anchor plate from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle/anchor plate to the vehicle. 2. Install the clip(s) that retain the seat belt buckle/anchor plate to the latch bracket. 3. Adjust the left seat back to a cargo position. 4. Adjust the seat filler panel in order to access the center rear seat back bracket/seat belt buckle anchor plate. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the center seat back/seat belt buckle mounting nut. Tighten Page 4337 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 10259 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 7490 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Page 10976 IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to 10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater corn hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Trailblazer EXT, and Envoy XL TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE Page 10634 Air Temperature Actuator - Right Mode Actuator - Auxiliary (Body Type VIN 6) Page 12050 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5983 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Exhaust - Exhaust Noise/Leak Exhaust Manifold: All Technical Service Bulletins Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 5645 5. Remove the fuel fill pipe ground strap bolt (3). 6. Loosen the fuel fill hose clamp (8). 7. Disconnect the fuel fill hose (9) from the fuel fill pipe (7). 8. Remove the fuel fill pipe (7). 9. Cap the open end of the fuel fill hose (9). INSTALLATION PROCEDURE Page 10224 Ball Joint: Testing and Inspection Ball Joint Inspection Tools Required J 8001 Dial Indicator or Suitable Dial Indicator Upper Ball Joint Inspection Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint. 3. Support the lower control arm with a floor stand as far outboard as possible and raise suspension to just below the ride height. 4. Install the J 8001 or a suitable dial indicator in a way to measure the vertical lash in ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to the upper control arm and check the dial indicator. 7. If the dial indicator reading is more than 1.524 mm (0.060 in), replace the upper ball joint. Lower Ball Joint Inspection Page 4616 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 14546 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE Page 13588 13. Remove the following headliner harness clips from the left center pillar: * The center pillar harness clips (4) * The center pillar harness clips (3) * The center pillar harness clips (1) 14. Remove the center pillar harness ground bolt (2). 15. Remove the harness from the left center pillar. 16. Remove the rear seats. 17. Remove the headliner harness retaining clips (2) from the rocker panel and floor panel. 18. Remove the center pillar headliner harness electrical connector from the bussed electrical center, and the block base from the floor panel. 19. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 20. Disconnect the inside rear view mirror electrical connector (6). 21. Disconnect the rain sensor electrical connector, if equipped. 22. Disconnect the navigation antenna electrical connector, if equipped. 23. Remove the upper rear quarter trim panels. 24. Remove the coat hooks from the roof panel. 25. Disconnect the electrical connector from the cellular phone antenna. 26. Remove the 2 push pins from the rear of the headliner. 27. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 28. Fully recline the bucket seats. 29. With the aid of an assistant, release the interlocking strips (1) that retain the headliner to the roof panel. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 15306 Electrical Symbols Part 8 Page 10058 10. Remove the power steering pump pulley using J25034-C. Installation Procedure 1. Install the power steering pump pulley using J25033-C. 2. Install the power steering pump pulley (1) flush against the end of the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump. 4. Install the power steering pump mounting bolts. Tighten the power steering pump mounting bolts to 25 Nm (18 ft. lbs.). Page 15729 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 11598 Antenna Cable: Service and Repair Antenna Cable Replacement REMOVAL PROCEDURE 1. Open the instrument panel (I/P) compartment to a full down position. 2. Disconnect the radio antenna cable (2) from the radio extension cable. 3. Remove the lower rear portion of the wheelhouse panel. 4. Reach up behind the wheelhouse panel and remove the antenna cable and grommet assembly from the cowl opening (1). 5. Pass the end of the radio antenna cable assembly through the cowl opening (1). Specifications Spare Tire: Specifications Spare Wheel Hoist Assembly Mounting Bolts 37 ft. lbs. Page 9489 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 11506 Impact Sensor: Diagrams Electronic Frontal Sensor Electronic Frontal Sensor - Left Electronic Frontal Sensor - Right Page 10574 Wheel Fastener: Specifications Wheel Nut 103 ft. lbs. Page 7851 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 1449 Electrical Symbols Part 3 Page 14518 Lumbar Adjuster Switch - Passenger(W/Memory Seat) Page 11492 4. Remove the seat belt bezel from the seat belt. 5. Remove the seat back cover and pad. 6. Remove the seat belt from the retractor bracket by guiding it through the slot. 7. Remove the rear seat belt center retractor retaining nut. 8. Remove the center retractor assembly by pulling the push pin from the seat back frame. Page 14354 Disclaimer Adjustments Trunk / Liftgate Striker: Adjustments ADJUSTMENT PROCEDURE 1. Check the lift gate window for proper fit to the lift gate window weatherstrip. ^ Open and close the lift gate window. ^ If the lift gate window is hard to close, additional striker shims will need to be added. ^ If the lift gate window does not seal tightly against the weatherstrip, striker shims will need to be removed. 2. Open the lift gate window. 3. Loosen the nuts retaining the lift gate striker to the lift gate window. 4. Remove or add shims as determined above. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten Tighten the nuts to 6 N.m (53 lb in). 6. Check the lift gate window for proper fit, readjust if necessary. 7. Close the lift gate window. Page 13029 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 5826 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 2336 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1727 Conversion - English/Metric Page 14295 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 8838 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 5594 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5453 Electrical Symbols Part 1 Page 1406 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 4488 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Page 5044 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15180 Page 7250 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 5311 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13131 IMPORTANT: In any area damaged beyond recognition, space the plug weld holes every 40 mm (1 1/2 in.) apart. 1. Drill 8 mm (5/16 in.) plug weld holes in the service part as necessary in the locations noted from the original part. 2. Prepare all of the attachment surfaces as necessary. 3. Apply a weld-thru primer to all of the bare metal surfaces. 4. Position the hinge bracket. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. IMPORTANT: Prior to refinishing, refer to publication GM4901M-D-01 GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendation. 7. Apply sound deadening materials. 8. Apply an approved anti-corrosion primer. Page 10863 4. Install the IP accessory trim plate. HVAC Control Module Replacement - Auxiliary REMOVAL PROCEDURE 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4. Remove the HVAC control-auxiliary. INSTALLATION PROCEDURE Page 3844 Electrical Symbols Part 3 Page 546 Locations View - HVAC Systems - Manual Service and Repair Front Door Latch: Service and Repair Latch Replacement - Front Door Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the rear half of the water deflector. 4. Disconnect the lock rod retaining clip from the outside door handle. 5. Remove the lock rod from the outside door handle. 6. Disconnect the lock cylinder rod from the cylinder, if equipped. 7. Remove the inside door handle. 8. Remove the 3 screws that retain the latch to the door. 9. Position the latch in order to disconnect the electrical connectors as needed. 10. Remove the latch from the door. 11. Noting the position of the inside handle lock rods, remove the inside handle lock rods from the latch. 12. Noting the position of the outside handle lock rods, remove the outside handle lock rods from the latch. 13. Remove the actuator from latch. Installation Procedure 1. Install the actuator to the latch. Page 15605 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 11359 6. Remove the seat back cover and pad. 7. Remove the seat back panel from the seat back frame. 8. Remove the seat belt from the retractor bracket by sliding the seat belt through the slot. 9. Remove the lower seat belt retractor retaining bolt and nut. 10. Remove the retractor assembly by pulling the push pin (2) from the seat back frame. Page 15837 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11805 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 3689 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 13449 Remove the auxiliary seal and the auxiliary seal retainer. Clean the surface and fill the void with Medium Body Seam Sealer, P/N 12378500 (in Canada, P/N 10952233). Let stand for 60 minutes and touch up. Correction 2 Remove the auxiliary seal and the auxiliary seal retainer. Clean the area with a non oil base cleaner and fill the void with urethane sealer. Correction 3 Install four new plastic nuts in the "A" Pillar. The new nuts have a foam gasket that seals the perimeter when seated. Correction 4 Seat the push-in retainers fully at the bottom of the "A" pillar. Correction 5 Apply weatherstrip adhesive inside the primary seal retainer. Seal the retainer from the top of the dash to the bottom of the "A" pillar. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14722 DISCLAIMER Page 10407 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 14854 Equivalents - Decimal And Metric Part 1 Page 1880 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5533 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday - Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 994 Page 10279 Installation Procedure 1. Install the lower control arm. 2. Install the rear axle lower control arm to the frame mounting nut and bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle lower control arm to the axle mounting bolt and nut. Tighten the lower control arm mounting bolts to 100 Nm (74 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 14577 Disclaimer Page 755 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 13865 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 13866 Disclaimer Page 9568 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 11791 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 51 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 10348 8. Remove the air spring from the vehicle. Installation Procedure 1. Install the air supply line to the air spring. Ensure the air supply line is fully seated. Caution: Ensure that the air spring is fully seated and properly positioned on the axle pilot. Failure to properly position the air spring may cause the air spring to break apart, possibly resulting in personal injury or damage to the vehicle. 2. Install the air spring (2) to the frame by aligning the mounting tabs (3) with the keyhole slots (1) in the upper spring seat. 3. Apply upward pressure to the air spring (2) and rotate clockwise until the antirotation peg snaps into place. 4. Pressurize the air suspension system. 5. Lower the vehicle. 6. Install the air suspension system fuse. 7. Start the vehicle and run for approximately 1 minute to ensure that the air suspension system is functioning properly. 8. Inspect the D height. Page 14681 4. Attach the molding to the outside of the door with double sided tape. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip. 9. Install the inner window belt sealing strip. 10. Install the trim panel. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. INSTALLATION PROCEDURE Page 4298 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 15931 5. Position the horizontal tab above the headliner and push the lens forward to seat the tab. 6. Push upward on the rear portion of the lens, in order to seat the rear lens retaining tab. 7. Pull down on the lens to ensure that the lens is secured to the headliner. Page 14671 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. INSTALLATION PROCEDURE 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Auxiliary REMOVAL PROCEDURE Page 5326 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9089 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 1697 Electrical Symbols Part 4 Page 13679 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 15114 Electrical Symbols Part 5 Page 9244 1. Install the generator and secure the generator with 3 bolts Tighten Tighten the generator bolts to 50 N.m (37 lb ft). 2. Connect the battery positive cable to the generator and secure the positive cable with the nut Tighten Tighten the generator positive cable nut to 9 N.m (80 lb in). 3. Install the engine lift hook and secure the lift hook with 2 bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). Locations Locations View Page 1167 Engine Coolant Temperature (ECT) Sensor Page 14409 8. Install the push pins (1) on the underside of the seat bottom. 9. Install the latch bezels. 10. Install the seat cushion bracket. 11. Install the seat cushion in the vehicle. Trailblazer EXT, and Envoy XL TOOLS REQUIRED J 36796 Clip Removal Tool REMOVAL PROCEDURE Page 5751 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 12959 Front Door Weatherstrip: Service and Repair Front Door Opening REMOVAL PROCEDURE 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Page 2493 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Page 4921 Locations View Page 938 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 9112 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. Page 3548 Heater Control Valve: Diagrams Coolant Bypass Valve (Body Type VIN 6) - HVAC Systems - Manual Coolant Bypass Valve (Body Type VIN 6) - HVAC Systems - Automatic Page 15981 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 1267 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 15128 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 8462 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 14360 10. Using a flat-bladed tool, carefully engage the plastic strips that retain the seat back cover to the side airbag inflator module. 11. Carefully install the seat back cover behind the trim edge of the side airbag inflator module. 12. Fasten the J-strips (1, 4) across the bottom of the seat back cover. 13. Install the seat cover flaps (2) to the seat frame with push pins (3). 14. Install the seat trim panel. 15. Install the head restraint. 16. Install the front seat assembly from the vehicle. Page 5149 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 2479 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 5815 Electrical Symbols Part 8 Page 9773 C304 Part 2 C305 Recall 04V046000: Erratic Wiper Operation Wiper Control Module: Recalls Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13099 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. INSTALLATION PROCEDURE 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Auxiliary REMOVAL PROCEDURE Specifications Crankshaft: Specifications Crankshaft Main Journal Diameter 2.7567-2.7574 inch Main Journal Taper - Maximum 0.0002 inch Out Of Round - Maximum 0.0002 inch Cylinder Block Main Bearing Bore Diameter 3.0760-3.0766 inch Crankshaft Main Bearing Inside Diameter 2.7579-2.7592 inch Main Bearing Clearance 0.0004-0.0025 inch Crankshaft End Play 0.0044-0.0153 inch Page 4404 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 999 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 8140 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 56 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 2265 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 9743 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7764 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Body - Front Fascia is Loose Front Bumper Cover / Fascia: All Technical Service Bulletins Body - Front Fascia is Loose File In Section: 08 - Body and Accessories Bulletin No.: 02-08-62-001 Date: August, 2002 TECHNICAL Subject: Front Fascia Loose (Replace Front Fascia Pencil Braces) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22375120 Condition Some customers may comment that the front fascia on the vehicle appears to be loose. This condition may be noticed while the customer is washing the vehicle. Correction Replace the front fascia pencil braces using the following service procedure. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 744862). 2. Remove the lower push-in retainer and the upper bolt from both the right and left front fascia pencil braces. 3. Remove the right and left front fascia pencil braces. 4. Replace the front fascia pencil braces with new pencil braces. Refer to the applicable part numbers listed below. 5. Install and "finger tighten" the upper brace bolts on both sides. 6. Install the lower brace push in retainers on both sides. Tighten Tighten the upper brace bolts to 10 N.m (89 lb in). 7. Lower the vehicle. Page 9314 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8231 Seals and Gaskets: Service and Repair Transfer Case Output Shaft Seal Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Output Shaft Seal Replacement - Front (Trailblazer EXT, Envoy XL) ^ Tools Required J 45236 Output Shaft Seal Installer - Front Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the front propeller shaft. 4. Remove the dust shield from the front output shaft. 5. Lightly tap the screw driver around the edge of the front output shaft seal. Page 13325 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Page 8353 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14267 Position Sensor - Rear Motor (W/Memory Seat) Locations Locations View OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 13641 5. Remove the lower seat belt anchor bolt. 6. Release the clips that retain the trim panel to the body. 7. Remove the trim panel from the vehicle. Installation Procedure 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Seat the clips the retain the trim panel to the body. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the seat belt lower anchor. Tighten the anchor bolt to 70. N.m (52 lb ft). 6. Install the left rear door sill panel. 7. Install the liftgate sill plate. 8. Install the left body side upper trim panel. Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL) Trim Panel Replacement - Rear Quarter - Right (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the right body side window rear garnish molding. 4. Remove the right body side window forward garnish molding.. 5. Remove the liftgate sill plate. 6. Remove the right rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Release the five screws that retain the rear quarter trim panel to the body. 9. Remove the rear quarter trim panel from the vehicle. Page 3423 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 4286 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 3807 INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. Page 10120 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1903 5. Loosen the bolts (1) retaining the discriminating sensor to the frame. 6. Remove the discriminating sensor assembly from the frame (1). 7. Position the discriminating sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the discriminating sensor. 9. Remove the connector-position assurance (CPA) from the discriminating sensor electrical connector. Page 12756 For vehicles repaired under warranty, use the table. DISCLAIMER Diagrams Hood Ajar Switch (Export) Page 11141 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement REMOVAL PROCEDURE 1. Remove the grille. 2. Remove the ambient air temperature sensor (1) to the headlamp assembly. 3. Remove the ambient temperature sensor from the panel assembly. 4. Disconnect the electrical connector from the ambient air temperature sensor. INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (1) to the headlamp assembly. 2. Connect the electrical connector to the ambient temperature sensor. 3. Install the ambient temperature sensor retaining clip to the headlamp panel assembly. 4. Install the grille. Page 12550 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 11834 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 1769 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 14989 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 9957 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 12670 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 391 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12156 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 4186 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 5480 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 124 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 11059 Refrigerant Oil: Fluid Type Specifications PAG (Polyalkaline Glycol) synthetic refrigerant oil (US GM part number 12345923) or equivalent. (Canadian GM part number 10953486). Page 15353 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 3081 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ....................................................................................................... 5W-30 (preferred), 10W-30 if over 0° F Page 15299 Electrical Symbols Part 1 Page 15716 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 11073 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 7113 Disclaimer Page 3911 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 3212 Electrical Symbols Part 1 Page 4964 Electrical Symbols Part 3 Page 1781 Electrical Symbols Part 1 Page 5689 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 3851 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5956 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1280 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Page 377 Electrical Symbols Part 1 Page 6024 Electrical Symbols Part 8 Service and Repair Parking Lamp Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the park lamp relay (1) from the bussed electrical center. INSTALLATION PROCEDURE Page 8057 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13697 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Engine Controls - MIL ON/Delayed Downshift/Fan Noise PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/Delayed Downshift/Fan Noise File In Section: 06 - Engine/propulsion System Bulletin No.: 01-06-04-052B Date: May, 2004 OBD SOFTWARE UPGRADE Subject: On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the powertrain control module (PCM) on all affected vehicles, as identified above, including vehicles in new dealer inventory, used inventory, and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table. *This a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide. Page 8903 4. Rotate the rear brake caliper upward until the brake caliper assembly is in the proper position. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the upper brake caliper mounting bolt. ^ Tighten the brake caliper bolt to 31 Nm (23 ft. lbs.). 6. Install the tire and wheel assembly. 7. Lower the vehicle. Refer to Vehicle Lifting. 8. Fill the brake master cylinder reservoir (if needed). Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 9. Pump the brake pedal slowly and firmly in order to seat the brake pads. 10. Burnish the new brake pads. Page 3572 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Page 14953 Driver/Vehicle Information Display: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 11023 Disclaimer Page 12369 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Locations Locations View Page 3740 Exhaust Manifold: Specifications Exhaust Manifold Bolt First Pass 18 ft. lbs. Second Pass 18 ft. lbs. Final Pass 18 ft. lbs. Page 11714 Page 3064 Engine Oil Pressure: Testing and Inspection Oil Pressure Testing Oil Pressure Testing ^ Tools Required J 21867 Pressure Gauge and Hose - J 42907 Oil Pressure Tester Adapter If the vehicle has low oil pressure perform the following tests. 1. Check the oil level. 2. Raise the vehicle and remove the oil filter. 3. Assemble the plunger valve in the large hole of J42907 (1) base and the hose in the small hole of J42907 (1) base. Connect the J21867 (2) to the end of the hose. 4. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve itself. 5. Install J42907 (1) on the filter mounting pad. 6. Start the engine and check the overall oil pressure and the oil pressure switch. The engine should be at operating temperature before checking the oil pressure. The oil pressure should be approximately 85 kPa (12 psi) at 1200 rpm using 5W30 engine oil. 7. If adequate oil pressure is indicated, check the oil pressure switch. 8. If a low reading is indicated, press the valve on the tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve would indicate a faulty pump. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 5775 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10635 Mode Actuator - Auxiliary (Body Type VIN 3) Page 6550 Disclaimer Page 11696 Equivalents - Decimal And Metric Part 1 Page 1539 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4195 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14942 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4263 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8344 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 11788 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 8854 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 764 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8463 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 3912 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 9648 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood C1 HVAC Systems - Manual Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Manual A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 10853 HVAC Control Module C1 Part 2 Diagrams Engine Oil Level And Temperature Sensor Page 8210 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 8878 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 70 Nm (52 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Locations Page 8754 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Page 12351 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 12875 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Page 14948 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 5842 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 1654 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 6368 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 3278 14. Remove the valve spring retainer and the valve 15. Use the J 38320 and remove the seals. 16. Clean and inspect the cylinder head. Installation Procedure Important: Lubricate the valve stems with clean engine oil before installing. 1. Use the J 33820 to install the valve seals. There is only one size seal. Page 6198 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 15908 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 3758 Muffler: Service and Repair Muffler Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Note: If there is any damage to the exhaust muffler or to the front pipe of the exhaust muffler, replace whole exhaust muffler assembly. 2. Remove the nuts that secure the muffler to the catalytic converter pipe. 3. Remove the muffler/resonator out of all the insulators securing it to the vehicle. 4. Move the muffler carefully out of the vehicle. 5. If there is damage aft of the exhaust muffler: ^ Suitably support the exhaust system. ^ Cut the exhaust pipe (1), where the damage is located. ^ Remove the damaged exhaust pipe and resonator. Page 7670 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Turn the fog lamp switch to the OFF position. 2. Rotate the bulb socket counter clockwise in order to release the socket from the fog lamp housing. 3. Remove the socket from the fog lamp housing (2). 4. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Index the tabs on the bulb socket to the slots in the fog lamp housing. 3. Install the socket to the fog lamp housing (2). 4. Rotate the socket clockwise until fully seated. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 9602 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Body - Rattle Under Hood Hood Support Rod: All Technical Service Bulletins Body - Rattle Under Hood Bulletin No.: 04-08-63-005 Date: June 15, 2004 TECHNICAL Subject: Rattle Noise Under Hood (Reposition Hood Prop Rod) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a slight buzz or rattle noise coming from under the hood. This noise could be mistaken for a unusual engine noise. Cause The hood prop rod may be making contact with the fan shroud. Correction Adjust the hood prop rod. 1. Support the hood. 2. Make sure the plastic prop rod pivot block is fully seated into the radiator support before making the adjustment. 3. Adjust the prop rod by bending the rod at the point of contact. Refer to the arrow in the illustration above. There should be approximately 10 mm (3/8 in) between the prop rod and the shroud. Warranty Information For vehicles repaired under warranty, use the table. Page 8510 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 1. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 3. Install the motor/encoder electrical connector. 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 14880 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 11958 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Engine - New Flywheel to Crankshaft Bolts Flywheel: Technical Service Bulletins Engine - New Flywheel to Crankshaft Bolts File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-020 Date: May, 2002 INFORMATION Subject: Change to Flywheel to Crankshaft Attaching Bolts Models: 2002 Chevrolet and GMC S/T Utility Model (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with 4.2L Inline 6 Cylinder Engine (VIN S - RPO L8) and Engine Build Date after July 16, 2001 Beginning with engines produced after July 16, 2001, the thread size of the bolts that attach the flywheel to the crankshaft has changed. The threads changed from a 10M X 1.5 to a 10M X 1.0. If a crankshaft needs to be replaced for any reason, there is a crankshaft kit available, P/N 88958866. The new kit includes a crankshaft and new bolts. Exercise caution when replacing a crankshaft that you do not mix the bolts. Mixing the old and new bolts could lead to stripped bolts or bolt holes and possible engine, crankshaft or transmission failure. Parts Information Parts are currently available from GMSPO. DISCLAIMER Page 9545 58. Install the IP upper trim panel and windshield pillar moldings. 59. Reinstall the SIR fuse #18 in the underhood electrical center and close the hood. 60. Connect the Tech 2(R) and clear codes. Bose(R) Premium Sound Without Rear Audio Controls These vehicles use wiring harness P/N 15164931, which you will modify slightly by cutting some unused wires. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove the shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconnect the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). 22. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. Important: OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 14534 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 1831 For vehicles repaired under warranty, use the table. Disclaimer Page 6165 Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 1524 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 15542 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by November 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement~ they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Note: Page 14469 2. Install the seat riser latch assembly (2) to the outer riser assembly stud (1). Page 9645 Fuse Block - Rear C2 Part 2 Page 7982 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 3913 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6443 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 12424 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 3536 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Locations Locations View Page 7558 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 762 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1878 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Specifications Case Adapter: Specifications NVG126-NP4 Transfer Case Adapter to Transfer Case Nuts ...................................................................................................................................... 47 Nm (35 ft. lbs.) Transfer Case Adapter to Transmission Bolts ...................................................................................................................................... 47 Nm (35 ft. lbs.) NVG 226-NP8 Transfer Case Adapter to Transfer Case Nuts ...................................................................................................................................... 47 Nm (35 ft. lbs.) Transfer Case Adapter to Transmission Bolts ...................................................................................................................................... 47 Nm (35 ft. lbs.) Page 1104 Lumbar Adjuster Switch - Passenger(W/Memory Seat) Page 8304 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 5233 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 14982 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5875 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 8930 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the rear brake caliper mounting bracket. 8. Remove the brake rotor retaining clips, if equipped. Page 14793 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 11824 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 9316 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4578 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 13376 For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 13619 1. Lower the headliner in order to gain access to the wire harness. 2. Position the sunshade to the headliner. 3. Connect the sunshade electrical connector to the headliner harness. 4. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. 5. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. Important: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. 6. Position the wire harness retaining clip between the headliner and the roof panel. 7. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. 8. Position the inboard retainer (1) to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the inboard retaining screw. Tighten the screw to 1.2 N.m (10 lb in). Page 1553 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 6322 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4235 Electrical Symbols Part 4 Page 4432 Fuel Pressure: Testing and Inspection SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Fuel System Diagnosis - Steps 1-3 Page 4397 Electrical Symbols Part 8 Page 10197 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 9569 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1768 Conversion - English/Metric Page 3885 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2(TM). 33. If a control module is replaced the following service procedures must be performed: - The Crankshaft Variation Learn Procedure - The Engine Oil Life Reset Procedure - The Idle Learn Procedure - The Inspection/Maintenance Complete System Set Procedure - The Vehicle Theft Deterrent Password Learn Procedure - The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: Ensure the control module and DLC connections are OK. - Ensure the Techline(TM) operating software is up to date. - Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. - The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2(TM) to communicate with the control module. - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: The Off-Board Programming Adapter - The Tech 2(TM) - The control module - The Techline(TM) terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline(TM) terminal, select Service Programming. 3. Select Tech 2(TM), Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(TM) as described on the Techline(TM) terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2(TM), select Service Programming Request Information function. The Tech 2(TM) communicates with the control module and receives the access code. 6. With the Tech 2(TM), exit the Service Programming Request Information. 7. Disconnect the Tech 2(TM) from the Off-Board Programming Adapter. 8. Connect the Tech 2(TM) to the Techline(TM) terminal. 9. Turn ON the Tech 2(TM). 10. With the Techline(TM) terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline(TM) terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline(TM) terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline(TM) terminal automatically loads the calibration files to the Tech 2(TM). 16. After the download is complete, turn OFF the Tech 2(TM) 17. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 18. Connect the Tech 2(TM) to the Off-Board Programming Adapter. 19. With the Tech 2(TM), select Service Programming. Page 14827 Electrical Symbols Part 4 Page 2180 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Page 8156 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 12168 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12090 Disclaimer Page 13326 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Description and Operation Oil Change Reminder Lamp: Description and Operation WHEN TO CHANGE ENGINE OIL Your vehicle has a computer that lets you know when to change your engine oil. This is not based on mileage, but on engine revolutions and engine operating temperature. When the computer has calculated that the oil needs changing, the GM Oil Life System will indicate that a change is necessary. The mileage between oil and filter changes will vary depending on how you drive your vehicle - usually between 3,000 miles (5,000 km) and 12,000 miles (20,000 km) since your last oil and filter change. Under severe conditions, the system may come on before 3,000 miles (5,000 km). Never drive your vehicle more then 12,000 miles (20,000 km) or 12 months (whichever occurs first) without an oil change. The system won't detect dust in the oil. So if you drive in a dusty area, be sure to change your oil and filter every 3,000 miles (5,000 km) or sooner. Page 5749 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15701 1. Install the high mount stoplamp to the lift gate window reveal molding, ensuring the center retaining tab is fully seated. NOTE: Refer to Fastener Notice in Service Precautions, 2. Install the 2 screws that retain the high mount stoplamp to the lift gate window reveal molding. Tighten Tighten the 2 retaining screws to 2.5 N.m (22 lb in). 3. Close the liftgate window. 4. Open the liftgate. 5. Install the grommet (1) to the body. 6. Connect the high mount stoplamp electrical connector (2). 7. Attach the rear portion of the headliner to the roof panel, by seating the 2 headliner retaining pins. 8. Position the lift gate opening weatherstrip over the headliner. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 11230 Inflatable Restraint Steering Wheel Module Coil C3 Inflatable Restraint Steering Wheel Module Coil C4 Page 11894 Disclaimer Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 151 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EHCU to Bracket 7 ft. lbs. EHCU Bracket Mounting Bolts 18 ft. lbs. Page 520 Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 1621 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4786 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 8898 3. Ensure that the brake pad retaining clip in the brake caliper is properly seated. 4. Install the inboard brake pad. 5. Install the outboard brake pad. 6. Rotate the brake caliper down into position. Page 15125 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 10389 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 8755 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the rotor. Important: Do not hammer on a wheel stud. 4. Remove the wheel stud bolt using J43631. Installation Procedure 1. Install the wheel stud to the wheel hub and bearing. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 4 washers and the nut to the wheel stud. Tighten the wheel stud nut to 130 Nm (95 ft. lbs.), drawing in the wheel stud. 3. Remove the nut and the washers. 4. Install the rotor. 5. Install the tire and the wheel. 6. Lower the vehicle. Page 122 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 1306 Electrical Symbols Part 1 Page 4003 Electrical Symbols Part 7 OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 5036 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Interior - Power Memory Seat Inoperative Power Seat Control Module: All Technical Service Bulletins Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 5598 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 7141 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15779 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 6195 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 14974 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 11275 16. Twist together 2 connector wire leads-the low circuits from both stages of the steering wheel module-to the deployment harness wire. Refer to SIR Connector End Views in order to determine the correct circuits. 17. Inspect that the 3 wire connection is secure. 18. Bend flat the twisted connection. 19. Secure and insulate the 3 wire connection to the deployment harness using electrical tape. Page 3902 Electrical Symbols Part 7 Page 11857 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1322 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Propeller Shaft Replacement - Front Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Front Propeller Shaft Replacement - Front Removal Procedure Important: Observe the position of all the driveline components. Accurately mark the relationship of the components before removal. These components include the propeller shafts, the drive axles, the pinion flanges, and the output shafts. Reassemble all components in the exact relationship to each other as they were before removal. Follow the specifications, the torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 3. Remove the yoke retainer bolts and yoke retainers from the front axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Disconnect the propeller shaft from the front axle pinion yoke. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 5. Remove the propeller shaft from the transfer case. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of grease. If the output shaft does not have a sufficient coating of grease, lubricate the shaft with grease (GM P/N 12377985 or equivalent). Important: Ensure that the propeller shaft assembly is fully engaged into the slip yoke. The retaining ring will produce a snapping noise when the shaft is properly engaged. 2. Install the propeller shaft to the transfer case. 3. Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the yoke retainers and the bolts. Page 5114 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 10121 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 267 Page 1461 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8236 Seals and Gaskets: Service and Repair Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case assembly. Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions. Notice: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component. 3. Insert a flat bladed screw driver between the input shaft seal and the transfer case. 4. Pry the front input shaft seal from the transfer case. 5. Remove the front input shaft seal. Installation Procedure Page 5591 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Locations Locations View Page 5546 1. Apply a few drops of clean engine oil to the male fuel pipe end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 8835 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 784 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the Underhood Compartment above the left front wheel well. Page 6683 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 3848 Electrical Symbols Part 7 Page 12952 Front Door Striker: Service and Repair Striker Replacement - Door Removal Procedure 1. Open the door. 2. Mark the position of the striker on the door frame. 3. Remove the 2 bolts that retain the striker to the door frame. 4. Remove the striker and spacer from the door frame. Installation Procedure 1. Install the striker and spacer to the door frame. Important: Do not tighten the bolts at this time. 2. Install the bolts that retain the striker to the door frame. 3. Position the striker and spacer to the door frame as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 4. Fully tighten the bolts that retain the striker to the door frame. Tighten the bolts to 25 N.m (18 lb ft). 5. Close the door. Page 5879 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2794 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203 - 229 mm (8 - 9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance Page 779 control module damage may occur. - If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. AFTER PROGRAMMING A CONTROL MODULE The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: Fuel trim correction - Idle Air Control (IAC) learned position - Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: The crankshaft variation learn procedure - The engine oil life reset procedure - The idle learn procedure - The inspection/maintenance complete system set procedure - The vehicle theft deterrent password learn procedure - The Throttle Position (TP) sensor learn procedure Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 10727 Electrical Symbols Part 3 Page 8435 Page 7504 Flywheel: Technical Service Bulletins Tools - Flywheel Holding Tool, Modification File In Section: 06 Engine/Propulsion System Bulletin No.: 01-06-01-017 Date: June, 2001 INFORMATION Subject: Flywheel Holding Tool J 44226-3A Modification or Replacement Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada With 4.2L Engine (VIN S - RPO LL8) All Chevrolet, GMC (light duty only) and Oldsmobile dealerships received tool J 44226-3A as part of the essential tool package. This tool may need modification to the welded area between the socket portion of the tool and the flat bar. Excessive weld in this area may cause the tool to not fully engage the bolt on the flywheel. If the tool does not fully engage the bolt, it could slip off during use, causing improper torque. Recommended Action Inspect tool J 44226-3A in the area shown. Remove excessive weld using a grinder. If a grinder is not available, or you cannot adequately remove the excess weld, call Kent-Moore Tools at 1-800-GM TOOLS for a free replacement. Disclaimer Page 10742 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 5984 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Oil Viscosity Engine Oil: Description and Operation Oil Viscosity ENGINE OIL VISCOSITY, UNITED STATES AND CANADA NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. SAE 5W-30 is the only viscosity grade recommended for your vehicle. Use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If the temperature range is-18°F( 0°C) or above SAE 10W-30 oil which has the API Starbust symbol is acceptable if SAE 5W 30 oils is not available. Areas where the temperature falls below -29°F (-20°C), either an SAE 5W-30 synthetic oil or and SAE 0W-30 oil is recommended. Both will provide easier cold starting and better protection for the engine at extremely low temperatures. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. SAE 5W-30 is the recommended engine oil viscosity. Engine oil viscosity thickness has an effect on the fuel economy and the cold-weather operation engine starting and oil flow. Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. When the temperature is consistently above -18°C (0°F), 10W-30 may be used. SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any GMC vehicle at any time. ENGINE OIL QUALITY AND VISCOSITY (OTHER THAN THE UNITED STATES AND CANADA) NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. Page 231 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 11742 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 10652 1. Remove the I/P carrier. 2. Disconnect the electrical connector from the mode actuator. 3. Remove the screws from the mode actuator (3). 4. Remove the mode actuator. INSTALLATION PROCEDURE 1. Install the mode actuator (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator (3). Tighten Tighten the screws to the to 1.9 N.m (18 lb in). 3. Install the I/P carrier. Mode Actuator Console REMOVAL PROCEDURE Page 1395 Electrical Symbols Part 2 Page 6370 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 123 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 13922 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 5086 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Diagrams Blower Motor Resistor Assembly Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 15626 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the electrical connector and remove the stoplamp switch (1). Installation Procedure 1. Install the electrical connector on the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Page 2910 2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-400, through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller EN 45680-402 will occur. 3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117). 4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 5. Install the fixture EN 456850-401(4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block. 6. Install the bearing (3) and the nut (1). 7. Tighten the nut (1) to the bearing (3). Important: Use four old cylinder head bolts for the attaching bolts. 8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 N.m (11 lb ft). 9. Rotate the nut clockwise in order to remove the cylinder bore sleeve. Exhaust Manifold Replacement Exhaust Manifold: Service and Repair Exhaust Manifold Replacement Exhaust Manifold Replacement Removal Procedure 1. Remove the air cleaner resonator outlet duct. 2. Remove the transmission filler tube stud nut from the A.I.R. adapter and move filler tube out of the way. 3. Remove the oil level indicator tube. 4. Remove the oxygen sensor from the exhaust manifold. 5. Remove 4 manifold heat shield nuts and remove the heat shield. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Loosen and remove the exhaust pipe bolts from the exhaust manifold. 8. Lower vehicle. Page 15924 1. Install the bulb (1) to the socket. 2. Wipe the bulb to ensure the bulb is free of dirt or oil. 3. Position the license lamp lens to the liftgate. 4. Verify that the license lamp lens gasket is fully seated to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the 2 license lamp lens retaining screws. Tighten Tighten the screws to 1.4 N.m (12 lb in). Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Interior - Passenger Seat Belt Too Tight Seat Belt Retractor: Customer Interest Interior - Passenger Seat Belt Too Tight File In Section: 09 - Restraints Bulletin No.: 02-09-40-003 Date: September, 2002 TECHNICAL Subject: Passenger Seat Shoulder Belt Too Tight or Cinches Up (Replace Passenger Seat Belt Retractor Assembly) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition Some customers may comment that the passenger front seat shoulder belt is too tight or cinches up during buckle-up. This condition is more prevalent when the occupant is of larger stature and may also occur if the occupant, while wearing the belt, performs large unusual movements. Cause The child seat locking mechanism of the Automatic Locking Retractor (ALR) may be engaging when the belt is extended to its full length upon fastening. Belt system is functioning as designed. Correction A new passenger seat retractor assembly has been released for service with additional 250 mm (9.84 in) of length to the belt to improve this condition. Replace the passenger seat retractor assembly. Refer to the Front Seat Belt Replacement procedure in the Seat Belts sub-section of the Service Manual. Parts Information Parts are expected to be available September 13, 2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1860 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5752 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3320 1. Install the timing chain tensioner and secure the tensioner with the bolts. ^ Tighten the timing chain tensioner bolts to 25 Nm (18 ft. lbs.). 2. Install the timing chain tensioner guide and secure the guide with the bolts. ^ Tighten the timing chain tensioner guide to 10 Nm (89 inch lbs.). 3. Install the timing chain tensioner shoe and secure the shoe with the bolt. ^ Tighten the timing chain tensioner shoe bolt to 26 Nm (19 ft. lbs.). Page 11488 5. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the bolt to 70 N.m (52 lb ft). Page 11263 Side Air Bag: Service Precautions CAUTION: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: ^ The seat cushion frame ^ The seat recline, if equipped ^ The seat adjuster ^ The seat back frame Failure to do so may cause future personal injury. Page 1601 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 12431 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 4941 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 1200 Oil Pressure Sender: Specifications Oil Pressure Sensor 15 ft. lbs. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 10007 Band Apply Servo: Service and Repair 2-4 Servo Removal Procedure ^ Tools Required J 29714-A Servo Cover Depressor 1. Raise the vehicle. Refer to Vehicle Lifting 2. Support the transmission with a suitable jack. 3. Remove the transmission support. Refer to Transmission Support Replacement on page 8-1405 in Frame and Underbody. 4. Remove the front exhaust pipe assembly. 5. Remove the heat shield. 6. Carefully lower the transmission to gain access to the 2-4 Servo. 7. Install the J29714-A. 8. Tighten the bolt in order to compress the servo cover. Page 6196 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 9126 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Page 1350 Stop Lamp Switch OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ..................................................................... 48-54 psi KOEO Key On Engine Off Page 10072 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 1027 For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of windshield wiper transmission seal assemblies required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of June 28, 2004 and will be approximately 20% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. CUSTOMER REIMBURSEMENT - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. CUSTOMER REIMBURSEMENT - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted by July 31, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Page 16030 Miniwedge (Door Jamb Switch) - Liftgate OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Engine Controls - Hesitation/Idle Fluctuation PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hesitation/Idle Fluctuation Bulletin No.: 03-06-04-018A Date: December 08, 2003 TECHNICAL Subject: Cold Idle Fluctuation at Altitude, Hesitation on Acceleration or 1-2 Upshift Delay (Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VINs - RPO LL8) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 03-06-04-018 (Section 06-Engine). Condition Some customers may comment on one of the following conditions: - Idle fluctuation for a few seconds on the first start up after an overnight soak at higher altitudes. - Hesitation on acceleration, this typically occurs with engine coolant temperatures between 60-80°C (140-175°F). - 1-2 upshift delay at throttle openings of 25% or less and ECT between 7-30°C (45-85°F). Cause The existing PCM calibration may not be optimized for all conditions. Correction Reprogram the PCM with the latest service calibration available from Techline. The Calibrations are electronic calibrations and are NOT available from GMSPO. Calibrations were available from Techline starting February 22, 2003, on the TIS 2000 version 2.5 for 2003 data update or later. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12206 5. Install the upper and lower trim covers. 6. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in Restraint Systems. 7. Program the Theft Deterrent Control Module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Fuse Applications - Underhood Fuse Block Fuse Block: Application and ID Fuse Applications - Underhood Fuse Block Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Description and Operation Voltage Regulator: Description and Operation REGULATOR The voltage regulator controls the field current of the rotor in order to limit system voltage. The regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Page 5082 Electrical Symbols Part 8 Page 15793 Daytime Running Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 12500 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 3702 Equivalents - Decimal And Metric Part 1 Page 3562 Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core (2) from the HVAC module assembly (1). INSTALLATION PROCEDURE 1. Install the heater core (2) to the HVAC module assembly (1). 2. Install the heater core access cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater core access cover screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement Page 1111 Seat Adjuster Switch - Front Passenger (W/Memory Seat) Page 4994 Various symbols are used in order to describe different service operations. Page 242 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 14928 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8272 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Locations Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: All Technical Service Bulletins Rearview Mirrors (Outside) Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 11938 Page 10704 Locations View - HVAC Systems - Automatic A/T - Cooler Line Fitting Applications Fluid Line/Hose: All Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 12801 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10738 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 14495 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 323 Navigation Module: Service and Repair Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Fold and tumble the right rear seat to a cargo position. 2. Leaving the electrical connectors attached, remove the communication interface module from the Vehicle Communication Interface Module (VCIM) bracket. Refer to Communication Interface Module Replacement (Trailblazer, Envoy, Bravada) or Communication Interface Module Replacement (Trailblazer EXT, Envoy XL) in Interior Trim. 3. Using a flat bladed tool, release the retaining tab (1) on the VCIM bracket. 4. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 5. Remove the VCIM bracket from vehicle. 6. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 7. Remove the VCIM bracket from vehicle. INSTALLATION PROCEDURE Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 8791 1. Install EBCM (2) onto BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Page 4394 Electrical Symbols Part 5 Page 5514 2. Remove the fuel pump relay from Junction Block # 2. 3. Start the engine and let it run until it stalls. 4. Turn the ignition key and crank the engine an additional 3 seconds to ensure that the fuel pressure has been relieved. 5. Turn the ignition to the OFF position. 6. Disconnect the negative battery cable. 7. Raise the vehicle on a suitable hoist. 8. Clean all of the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Important: The quick connect retainers will remain on the fuel filter when the fuel pipes are disconnected in the next step. 9. Squeeze the tabs on the retainers inward and disconnect both fuel pipes from the fuel filter. 10. Remove the white retainers from the fuel filter and discard. 11. Install the new blue retainers on the fuel filter. 12. Connect both fuel pipes to the fuel filter and tug firmly on the pipes to ensure that they are fully engaged. 13. Lower the vehicle. 14. Connect the negative battery cable. 15. Install the fuel pump relay in the junction block. 16. Turn the ignition to the ON position and check for leaks. 17. Install the GM Recall Identification Label. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 5242 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) 1 Heated Oxygen Sensor (HO2S) 2 Page 4410 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 10826 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 1294 Fuel Gauge Sender: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. A/T - Cooler Line Fitting Applications Fluid Line/Hose: All Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 4999 Powertrain Control Module (PCM) C3 Page 10402 4. Install J24319-B to the shock module yoke to lower control arm stud. 5. Disconnect the shock module yoke from the lower control arm using J24319-B. 6. Remove the shock module yoke to shock absorber pinch bolt and nut. 7. Spread the shock module yoke at the pinch belt using a flat bladed tool. 8. Remove the shock module yoke from the shock absorber. Installation Procedure Page 1105 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Page 2449 Power Steering Line/Hose: Service and Repair Power Steering Hose Assembly Replacement Tools Required ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise the vehicle and support with suitable safety stands. Refer to Vehicle Lifting. 2. Install a drain pan under the vehicle. 3. Remove the power steering hose assembly to the power steering gear retaining bolt. 4. Disconnect the power steering hose assembly from the power steering gear. 5. Remove the power steering return hose and power steering cooler hose from the power steering cooler. 6. Lower the vehicle. 7. Disconnect the fuse block wiring harnesses from the wiring loops. 8. Remove the fuse block. 9. Remove the battery tray. Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi Page 1907 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Position the side impact sensor (2) to the door. 2. Connect the electrical connector (1) to the side impact sensor (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws which retain the side impact sensor to the door. Tighten Tighten the side impact sensor screws to 8 N.m (71 lb in). 4. Fully seat the water deflector to the door. 5. Install the door trim panel. 6. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 3117 10. Clip transmission cooler lines to block. 11. Connect prop shaft to front differential. 12. Install the steering gear crossmember. 13. Install the left and right wheel drive shaft. 14. Install the oil pan drain plug. ^ Torque the oil pan drain plug to 26 Nm (19 ft. lbs.). 15. Install the engine protection shield and secure with the bolts. ^ Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 16. Install the left and the right front tires. 17. Lower the vehicle. Important: Inspect the engine for oil leaks in order to ensure all sealing surfaces are sealed. 18. Service the engine with oil. Page 810 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 2204 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 1094 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Rear Motor (W/Memory Seat) Page 2442 Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Install the coolant recovery tank. 6. Install the washer solvent container. 7. Install the nuts (1,5) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the components using the J 39400. TrailBlazer EXT and the Envoy XL. EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Loosen the evaporator tube (5) from the evaporator. 3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping. 4. Remove the evaporator tube nut from the condenser. 5. Remove the nuts (1,2) retaining the evaporator tube to the tender. 6. Remove the washer solvent container. 7. Remove the coolant recovery tank. 8. Remove the evaporator tube using J 26549-E. 9. Remove the O-ring seal and discard. INSTALLATION PROCEDURE Page 2459 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Partially drain the cooling system. 2. Remove the upper radiator baffle. 3. Remove the vent inlet hose from the radiator. 4. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Install the vent inlet hose to the radiator. 3. Install the upper radiator baffle. 4. Fill the cooling system Locations Locations View Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 5084 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12762 For vehicles repaired under warranty, use the table. DISCLAIMER Page 6350 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 1434 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 14428 4. Install the seat module, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the seat module retaining screw. Tighten the screw to 5 N.m (44 lb in). 6. Install the 11 hog rings to the top side of the cover and pad. 7. Install the 2 hog rings (1) to the bottom rear side of the cover and pad. 8. Press the seat cover hook and loop retaining strips together by running your hand firmly over the seat cover. 9. Connect the seat cushion heater electrical connector. 10. Install the seat electrical harness to the seat pan. 11. Install the SIR electrical harness (2) to the seat pan. 12. Install the front/rear J strips (2,4). 13. Install the side J strips (1,3). Page 13629 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Garnish Molding Replacement - Rear Window Garnish Molding Replacement - Rear Window Removal Procedure 1. Open the liftgate. Page 1666 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 13473 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 14797 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12968 Front Door Window Glass Weatherstrip: Service and Repair Window Weatherstrip Run Channel Assembly Replacement - Front REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten Tighten the retaining bolts to 10 N.m (88 lb in). Page 3218 Electrical Symbols Part 7 Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 2. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 2279 Alignment: Service and Repair Wheel Alignment Measuring Procedures Inspection and Preparation Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Irregular or premature wear ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Alignment Angle Measurement Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 1852 Electrical Symbols Part 1 Page 4566 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 2255 Locations View Page 1624 Various symbols are used in order to describe different service operations. Page 2726 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 11673 Electrical Symbols Part 8 Page 11281 41. Twist together 2 connector wire leads-the high circuits from both stages of the IP module-to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits. 42. Inspect that the 3 wire connection is secure. 43. Bend flat the twisted connection. 44. Secure and insulate the 3 wire connection to the deployment harness using electrical tape. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 236 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 2873 6. Install the top chain guide. 7. Add threadlocker to the top chain guide bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. 8. Install the top chain guide bolts. Tighten the top chain guide bolts to 10 Nm (89 lb in). 9. Install the camshaft cover. Refer to Camshaft Cover Replacement. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 8091 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Recall 04V527000: Stop/Tail Lamp Inspect/Replace Brake Lamp: Recalls Recall 04V527000: Stop/Tail Lamp Inspect/Replace Make / Models : Model/Build Years: Buick / Rainier 2004 Chevrolet / TrailBlazer 2002-2004 Chevrolet / TrailBlazer ext 2002-2004 GMC / Envoy XL 2002-2004 Oldsmobile / Bravada 2002-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V527000 Recall Date : OCT 27, 2004 COMPONENT: EXTERIOR Lighting: Brake Lights Potential Number Of Units Affected : 871473 SUMMARY: On certain sport utility vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. CONSEQUENCE: An inoperative brake lamp will not convey the driver's intention of stopping to drivers in following vehicles, and an inoperative rear turn signal lamp will not convey the driver's intention to turn to drivers in following vehicles. Both of these failures can increase the risk of a crash. REMEDY: Dealers will inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. the recall began on November 22, 2004. Owners should contact Chevrolet at 1-800-630-2438, Oldsmobile at 1-800-630-6537, Buick at 1-866-608-8080, or GMC at 1-866-996-9463. NOTES: GM Recall NO. 04087. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 12169 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2146 Disclaimer Page 1441 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Page 16043 Turn Signal/Multifunction Switch C4 Page 3976 Various symbols are used in order to describe different service operations. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 7294 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 12986 5. Install the water deflector. 6. Install the door trim panel. Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip that retains the lock rod to the handle. 4. Remove the lock rod from the handle. 5. Remove the nut that retains the handle and bracket to the door. 6. Remove the bracket from the handle. 7. Remove the handle from the door. INSTALLATION PROCEDURE 1. Install the handle to the door. 2. Install the bracket to the handle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nut that retains the handle to the bracket. Tighten Tighten the nut to 10 N.m (88 lb in). 4. Install the lock rod to the handle. 5. Install the clip that retains the lock rod to the handle. Page 215 Disclaimer Page 736 Electrical Symbols Part 4 Page 6110 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 6143 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 12349 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 8150 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 9861 ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio to the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting 27. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 28. Locate the 8-way connector with the purple CPA. Separate the connector. Remove the CPA from the female side of the connector. 29. Route the new harness under the carpet from the rear of the console to the 8-way connector. 30. Remove the eight wires from the 8-way in line harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Insert the Gray wire into cavity A. ^ Insert the Tan wire into cavity B. ^ Insert the Dark Green wire into cavity C. ^ Insert the Light Green wire into cavity D. ^ Insert the Yellow wire into cavity E. ^ Insert the Brown wire into cavity F. ^ Insert the Light Blue wire into cavity G. ^ Insert the Dark Blue wire into cavity H. 31. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 32. Cut the wires and terminals from the wires you have removed from the 8-way connector as close to the taped portion of the original wiring harness as possible. 33. Reposition the rear electrical center through the carpet and reposition the carpet. 34. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 35. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 36. Insert the ignition key and turn to the RUN position Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 37. Turn the key OFF. Remove the key. Page 4929 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 10104 Electrical Symbols Part 4 Page 1515 Electrical Symbols Part 6 Page 11983 Labor Time Information Page 9753 connector/leads on the body harness by splicing in the service pigtail, P/N 15306403, using the procedure listed below. Passenger Door 1. Inspect the passenger door harness connector (9 wires) and terminals (inline to body harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors sub-section of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (9 wires) and terminals (inline to passenger door harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If there is evidence of corrosion, replace the mating connector/leads on the body harness by splicing in the service pigtail, P/N 88953131, using the procedure listed below. Service Pigtail Procedure 1. Remove the closeout/insulator panel. 2. Remove the door sill plate. 3. Pull back the carpet for access. 4. Remove the driver foot rest pad. 5. Release the harness to body clips. 6. Pull the existing body harness through the door jam and into the body. 7. Cut the existing harness and splice in the service pigtail. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 8. Feed the harness through the body and into the door jam. 9. Install the harness to body clips. 10. Install the driver foot rest pad. 11. Install the carpet in place. 12. Install the door sill plate. 13. Install the closeout/insulator panel. Page 12041 Electrical Symbols Part 2 Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the 2HI position. 1. Raise the vehicle. 2. Remove the fuel tank shield, if equipped. 3. Disconnect the motor/encoder electrical connector (1). 4. Remove the motor/encoder mounting bolts. Page 13068 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Carefully remove the water deflector from the door by releasing the adhesive backing. Installation Procedure 1. Position the water deflector to the door. 2. Press the water deflector to the door. Ensure that the water deflector forms a proper seal around the surface of the door panel. 3. Install the door trim panel. Page 1765 Equivalents - Decimal And Metric Part 1 Page 6777 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 13703 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10543 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Page 11926 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. HVAC Systems - Manual Heater Control Valve: Description and Operation HVAC Systems - Manual COOLANT BYPASS VALVE The coolant bypass valve controls coolant flow to the auxiliary heater core. Integral to the coolant bypass valve is an electric solenoid that controls vacuum flow to open and close the valve. When the HVAC control module applies 12 volts to the integral solenoid, the solenoid applies vacuum to a diaphragm that closes the water valve. This action restricts coolant flow to the auxiliary heater core. The coolant bypass valve is normally open to allow coolant flow. Page 2630 Fuse Block - Underhood C5 Fuse Block - Underhood C7 Interior - Cargo Cover Handle is Broken Cargo Cover: All Technical Service Bulletins Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 15610 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 15499 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 3619 Equivalents - Decimal And Metric Part 1 Page 4273 Electrical Symbols Part 1 Page 8859 Conversion - English/Metric Page 8498 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 10511 Disclaimer Page 12365 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 13101 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Remove the rear door sill plate. Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Door Handle Bezel Replacement Removal Procedure 1. Remove the door trim panel from the door. 2. Release the 4 tabs retaining the bezel to the trim panel. 3. Remove the bezel from the trim panel. Installation Procedure 1. Install the bezel to the door, ensuring that all 4 retaining tabs are fully seated. 2. Install the door trim panel to the door. Page 3680 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 8672 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 2183 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 295 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 1060 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Page 6823 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 103 Page 5913 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12665 Electrical Symbols Part 7 Page 333 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 7499 Flex Plate: Service and Repair Engine Flywheel Replacement ^ Tools Required J 36660-A Torque Angle Meter Removal Procedure 1. Remove the transmission. Important: Note the position and the direction of the engine flywheel before removal. 2. Remove the flywheel bolts. 3. Remove the flywheel. 4. Clean and Inspect the flywheel. Installation Procedure 1. Add Threadlock GM P/N 12345493 (Canadian P/N 10953488) to the new flywheel bolts. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the flywheel and secure the flywheel with the new bolts. 2.1. Tighten the bolts in sequence to 25 Nm (18 ft. lbs.). 2.2. Use the J 36660-A in order to tighten the bolts an additional 50°. 3. Install the transmission. Page 8221 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Page 6207 11. Using J2845fl release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 12147 Electrical Symbols Part 5 Page 14127 7. Position the wire harness retaining clip between the headliner and the roof panel. 8. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. 9. Position the inboard retainer (1) to the roof panel. Notice: Refer to Fastener Notice in Cautions and Notices. 10. Install the inboard retaining screw. Tighten Tighten the screw to 1.2 N.m (10 lb in). 11. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. Specifications Power Steering Line/Hose: Specifications Power Steering Hose Assembly to the 7 ft. lbs. Frame Brackets Mounting Bolts Power Steering Hose Assembly to the 7 ft. lbs. Front Crossmember Bracket Mounting Bolt Power Steering Hose Assembly to the 9 ft. lbs. Power Steering Gear Retaining Bolt Power Steering Hose Assembly (Pressure Hose) to 18 ft. lbs. the Power Steering Pump Power Steering Hose Assembly to the Wheel Well 7 ft. lbs. Bracket Mounting Bolt Page 14532 3. Install the switch bezel to the seat with the 3 screws. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE Page 14592 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1609 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12506 Page 6040 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4983 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 11276 20. Connect the deployment harness to the steering wheel module connector. 21. Route the deployment harness out of the driver side of the vehicle. 22. Disconnect the inflatable restraint side impact module-left connector (1), located under the driver seat. Page 10216 10. Maintain the pipe wrench on the opposite end of the rack (6). 11. Place a wrench on the flats of the inner tie rod housing (2). 12. Rotate the inner tie rod housing (2) counterclockwise until the inner tie rod separates from the rack (4). 13. Remove old LOCTITE from the threads (1) of the rack (3) and inner tie rod (2). Installation Procedure 1. Slide the shock dampener (4) forward onto the rack (3). Important: Threads must be clean prior to LOCTITE application. Check the LOCTITE (or equivalent) container expiration date. Use only enough LOCTITE to evenly coat threads. 2. Apply LOCTITE 262 (or equivalent) to the inner tie rod threads (2). 3. Attach the inner tie rod (2) onto the rack (3). 4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). Notice: Refer to Fastener Notice in Service Precautions. Important: The pipe wrench must be placed at the valve end of the steering gear (1) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (1). 5. Place a torque wrench and J34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod housing to 100 Nm (74 ft. lbs.). Page 2629 Fuse Block - Underhood C4 Page 12362 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Diagrams Seat Belt Switch - Driver Page 14182 Installation Procedure 1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the frame. 2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back cover and pad. 4. Install the front seat head restraint. 5. Install the seat assembly. Head Restraint Cover Replacement - Front Seat Head Restraint Cover Replacement - Front Seat Removal Procedure 1. Remove the front seat head restraint. 2. Release the J-strips on the bottom of the head restraint cover. 3. Remove the cover from the head restraint. Installation Procedure Page 8247 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13722 Driver Door Module (DDM) C2 Page 13615 10. Reach above the headliner to access the electrical connector (1). 11. Remove the electrical connectors from the headliner substrate. 12. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE 1. Lower the headliner in order to gain access to the wire harness. 2. Position the sunshade to the headliner. 3. Connect the sunshade electrical connector to the headliner harness. 4. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. Page 1093 Position Sensor - Recline Motor (W/Memory Seat) Page 11717 Page 14306 1. Remove the screws from the inboard/outboard rear seat back cushion hinge covers. 2. Remove the seat back cover and pad. 3. Remove the push pins (1) securing the seat back panel to the frame. 4. Remove the seat back panel. 5. Remove the rear center seat belt retractor assembly, if you are removing the frame from the left-hand rear seat. 6. Remove the seat back cushion mounting bolts (2) securing the rear seat back frame to the inboard/outboard rear seat back cushion hinge assembly. Page 272 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 126 (NP4) ................................................................................................................................... ............................................................. 1.8L (2.0 Qt) NVG 226 (NP8) ................................................ ................................................................................................................................................ 1.8L (2.0 Qt) Page 3629 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 4792 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12036 Fastener Tightening Specifications Page 10057 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Remove the air cleaner assembly. 3. Remove the drive belt. 4. Install a drain pan under the vehicle. 5. Disconnect the power steering pressure hose (1) from the power steering pump. 6. Disconnect the power steering cooler hose (2) from the power steering pump. 7. Disconnect the wiring harness from the wiring loom on the power steering pump. 8. Remove the power steering pump mounting bolts. 9. Remove the power steering pump. Page 7380 For vehicles repaired under warranty, use the table. Disclaimer Page 15414 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 11731 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 5161 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12191 Use a scrubbing action, non-abrasive cleaning cassette (part of J 39916-A ) for proper tape player cleaning. This cleaner is a wet-type cleaning system. The wet-type cleaning system uses a cleaning cassette with pads. The pads scrub the tape head as the hubs of the cleaner cassette turn. If you use this type of cleaner, the following conditions may occur: - The radio displays an error. - The cartridge ejects. These conditions are normal and is the result of an added feature in the tape player that detects broken tapes. If an error occurs, insert the cleaning cassette at least 3 times in order to thoroughly clean the tape player. You can also use a non-scrubbing action, wet-type cleaner. This type of cleaner uses a cassette with a fabric belt which cleans the tape head. This type of cleaning cassette will not cause an error, but may not clean the tape player as thoroughly as the scrubbing type cleaner. Page 6592 Disclaimer Page 3429 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 10109 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 9452 Parts Information Parts are expected to be available 8-22-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15988 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 2222 Equivalents - Decimal And Metric Part 1 Page 6767 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 8540 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 10486 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 490 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With the aid of an assistant, remove the sunroof assembly from the vehicle and place on a clean, prepared surface. Refer to Sunroof Replacement 4. Remove the sunroof drive motor. 5. Remove the screw that retains the module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the module. 7. Remove the module from the mounting bracket. INSTALLATION PROCEDURE IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 1. Position the module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw that retains the module to the mounting bracket. Tighten Page 13307 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Side Impact Sensor Impact Sensor: Diagrams Side Impact Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Page 12495 Page 3307 Oil Pressure Sender: Specifications Oil Pressure Sensor 15 ft. lbs. Page 10092 6. Crimp the large seal retaining clamp (4) on boot (1) with J22610. 7. Crimp the small seal retaining clamp (3) to inner tie rod assembly (2) with J22610. 8. Install the rack and pinion gear. 9. Install the outer tie rod. Page 12252 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 4537 Locations View Powertrain Control Module (PCM) Replacement Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector retaining bolts (1) in the center of the PCM harness connectors. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Remove the PCM harness connectors (3) from the PCM (2). 3. Remove the PCM mounting nuts and bolts (3). NOTE: Refer to PCM and ESD Notice in Service Precautions. 4. Remove the PCM (2) from the intake manifold. 5. Remove the PCM mounting studs (1) from the intake manifold, if necessary. Page 5794 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 6104 Electrical Symbols Part 8 Page 5261 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15242 Fuel Pump And Sender Assembly Page 7587 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15589 Electrical Symbols Part 5 Page 9361 Fuse Block: Locations Fuse Block - Underhood Fuse Block Underhood Locations View Located in the underhood compartment above the left front wheel well. Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 294 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 2014 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 4415 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 11534 1. Attach the radio antenna module to the headliner retaining strips. 2. Connect the coax cable to the radio antenna module. 3. Connect the electrical connector to the radio antenna module. 4. Connect the radio antenna module electrical connector to the stationary glass. 5. Install the rear headliner to roof retainers. 6. Install the left coat hook. Page 15706 Electrical Symbols Part 1 Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Journal Clearance 0.0008-0.0025 inch Page 14361 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Rear No. 1 Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the seat back from the vehicle. 2. Remove the seat belt buckle bracket, on the right side only. 3. Remove the seat belt anchor bolt from the bracket. 4. Release the seat belt bezel from the seat back by pressing in the buttons (1) on the plastic retainers. 5. Remove the seat belt bezel by sliding it off the seat belt. 6. Remove the head restraints. Page 13524 Console: Service and Repair Console Replacement Console Replacement Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the rubber ash tray inserts and rubber mat from the console. 3. Remove the floor shift control knob. 4. Remove the center console shift lever bezel, Oldsmobile only. 5. Remove the console storage compartment. 6. Remove the center console retaining screws. 7. Adjust the parking brake to the full-up, or fully engaged position. 8. Release the 2 forward trim extensions ears attached to the lower IP-Oldsmobile only. 9. Slide the console rearward and raise the rear of the console in order to expose the electrical connectors. 10. Disconnect the electrical connectors as necessary. 11. Adjust the parking brake to approximately the halfway position. 12. Remove the center console from the vehicle. Installation Procedure 1. Position the center console to the vehicle. 2. Adjust the parking brake to the full-up, or fully engaged position. 3. Connect the electrical connectors as necessary. 4. Lower the rear of the console and slide the console forward into position. 5. Ensure that the 2 retaining ears on the front extensions of the console are fully engaged to the lower IP-Oldsmobile only. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the center console retaining screws. Tighten the screws to 2.5 N.m (22 lb in). 7. Install the console storage compartment. 8. Install the center console shift lever bezel. 9. Install the floor shift control knob. 10. Install the rubber ash tray inserts and rubber mat to the console. Page 15457 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4320 Electrical Symbols Part 2 Page 4543 INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. Page 8736 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14080 Sunroof / Moonroof Module: Diagrams Sunroof Module Connector C1 Sunroof Module Connector C2 Page 7678 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Page 7297 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 11 Nm (97 inch lbs.). Page 5497 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 CIRCUIT DESCRIPTION The scan tool first energizes the fuel pump and then the injectors for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Fuel Injector Balance Test With Tech 2 - Steps 1-5 Page 3973 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4297 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3280 6. Remove the air pressure to the cylinder. 7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil. 8. Install the camshafts to their original position. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the camshaft caps onto their original journal. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 12. Install the spark plugs. Page 15329 Equivalents - Decimal And Metric Part 1 Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 13198 Endgate Module (EGM) C2 (XUV) Part 2 Page 14436 7. Remove the cover from the cushion by separating the retaining strips. 8. Separate and remove the cushion and cover assembly from the seat pan. 9. Release the reinforcement bar from the hog-rings. 10. Remove the cover from the cushion. Installation Procedure 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. 8. Install the push pins (1) on the underside of the seat bottom. 9. Install the latch bezels. 10. Install the seat cushion bracket. 11. Install the seat cushion in the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 (TrailBlazer EXT, Envoy XL) Seat Cushion Cover and Pad Replacement - Rear No. 1 (Trailblazer EXT, Envoy XL) Tools Required J 36796Clip Removal Tool Removal Procedure Page 14476 Seat Track: Service and Repair Manual REMOVAL PROCEDURE 1. Remove the front bucket seat assembly from the vehicle. 2. Remove the seat cushion trim panel. 3. Remove the lumbar support cable from the seat adjuster. 4. Remove the SIR harness connector (1) from the seat adjuster bracket. 5. Remove the SIR harness from the harness clips (2) and remove the SIR harness from the seat adjuster. 6. Remove the seat back from the seat adjuster. 7. Remove the seat belt buckle nut (1). Page 4140 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5810 Electrical Symbols Part 3 Page 11690 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14738 Electrical Symbols Part 7 Page 5347 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 13145 8. Open the hood and install the prop rod. 9. Install the left and right adjustable rubber bumpers and adjust them all the way down. 10. Close the hood and verify adjustment. The bumpers are required to make contact with the hood. Adjust if necessary. 11. Apply white lithium grease to the bottom of the V on the latch. Refer to illustration above. 12. Verify the final adjustment by grabbing the hood and jiggling it up and down. If a rattle is heard, perform the procedure again. 13. Install the grille. Refer to Grille Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12145 Electrical Symbols Part 3 Page 8360 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8367 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 3633 Radiator: Service and Repair Radiator Replacement Radiator Replacement (Body Vin Code 3) ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant from the radiator. 2. Recover the refrigerant. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the lower radiator support shield, if equipped. 5. Remove the transmission cooler lines from the radiator. 6. Reposition the outlet radiator hose clamp using J 38185. 7. Remove the outlet radiator hose (1). 8. Lower the vehicle. 9. Remove the cooling fan and shroud. 10. Remove the radiator support diagonal brace. 11. Remove the coolant recovery line from the radiator. Page 3035 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. 1. Remove the drive belts. 2. Position a hex-head socket on the belt tensioner pulley bolt head. 3. Move the drive belt tensioner through its full travel. - The movement should feel smooth. - There should be no binding. - The tensioner should return freely. 4. If any binding is observed, replace the tensioner. 5. Install the drive belt. Diagrams Page 62 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 2747 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 5427 Fuel: Description and Operation Use regular unleaded gasoline rated at 87 octane or higher. The manufacturer recommends that the gasoline meet the specifications which have been developed by the American Automobile Manufacturers Association (AAMA) and endorsed by the Canadian Motor Vehicle Manufacturers Association for better vehicle performance and engine protection. Gasoline meeting the AAMA specification may provide improved driveability and emission control system performance compared to other gasoline. For more information, write to: American Automobile Manufacturer's Association, 7430 Second Ave., Suite 300, Detroit, MI, 48202. Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. Severe knocking may damage your engine. If you are using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs service. Do not worry if you hear a little pinging noise when you are accelerating or driving up a hill. This is normal and you do not have to buy a higher octane fuel to get rid of pinging. Only the heavy, constant knock means that you have a problem. NOTE: Your vehicle was not designed for fuel that contains methanol. Do not use methanol fuel which can corrode metal parts in your fuel system and also damage plastic and rubber parts. This kind of damage would not be covered under your warranty. If your vehicle is certified to meet California emission standards, indicated on the underhood emission control label, the vehicle is designed to operate on fuels that meet California specifications. If such fuels are not available in states adopting California emission standards, your vehicle operates satisfactorily on fuels meeting federal specifications, but the emission control system performance may be affected. The Malfunction Indicator Lamp (MIL) on your instrument panel may turn ON, and your vehicle may fail a smog-check test. If this occurs, return to your authorized dealer for diagnosis in order to determine the cause of the failure. In the event that the cause of the condition is determined to be the type of fuels used, repairs may not be covered by your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called Methylcyclopentadienyl Manganese Tricarbonyl (MMT). Ask your service station operator whether or not the fuel contains MMT. Page 12352 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 4990 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 9424 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 5843 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 5867 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 7656 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. HVAC Systems - Automatic Control Assembly: Description and Operation HVAC Systems - Automatic Air Delivery Description and Operation HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for Keep Alive Memory (KAM). If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The Body Control Module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the features. AUXILIARY HVAC CONTROL MODULE-VIN 6 The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range. Air Temperature Description and Operation HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for Keep Alive Memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The Body Control Module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the features. AUXILIARY HVAC CONTROL MODULE-VIN 6 The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range. Page 7448 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 15601 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 13570 16. Attach the mechanic's wire to the end of the headliner harness. 17. Pull the bottom of the mechanic's wire away from the cowl insulation access hole in order to position the headliner harness behind the IP. 18. Attach the 3 clips (1) securing the wire harness to the windshield pillar. 19. Attach the lower rosebud (2) retaining the headliner harness to the cowl. 20. Connect the coax cable (2) and headliner harness connector (1). 21. Close the IP compartment door. 22. Install the IP trim pad. 23. Install the windshield garnish moldings. 24. Install the center pillar trim panels. 25. Install the front side door sill plates. 26. Install the right sound insulator. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 8685 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. Page 14978 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3417 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Engine - Redesigned Oil Pick-Up and Front Cover Oil Pick Up/Strainer: Technical Service Bulletins Engine - Redesigned Oil Pick-Up and Front Cover Bulletin No.: 04-06-01-015 Date:May 24, 2004 INFORMATION Subject: New Design Oil Pick Up Tube and Front Cover Models: 2004 Buick Rainier 2002-2004 Chevrolet Trailblazer 2002-2004 GMC Envoy 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Body/Frame - Roof Rack Wind Noise Roof Rack Frame: All Technical Service Bulletins Body/Frame - Roof Rack Wind Noise File in Section: 08 - Body and Accessories Bulletin No.: 02-08-67-005 Date: May, 2002 INFORMATION Subject: Proper Position and Installation of Roof Rack Cross Rails to Reduce Wind Noise Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBrazer, TrailBlazer EXT, Envoy, Envoy XL) 2002 Oldsmobile Bravada Some of the above vehicles may exhibit wind noise related to the roof rack. In an effort to reduce wind noise, Engineering has identified a specific position and installation for the roof rack cross rails. ^ Beginning on September 6, 2001 the TrailBlazer, Envoy, and Bravada were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the TrailBlazer EXT and Envoy XL were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the directional arrows were removed from the cross rails on all models to eliminate any confusion as to which direction is correct. It has been found that some dealers are changing the direction of the cross rails thinking they were installed incorrectly. To obtain the optimum position and installation of the roof rack cross rails that produce the least wind noise, use the following procedure: 1. If the cross rails have directional arrows, they should be installed in the reverse direction (arrows toward rear of vehicle). Remove the cross rails and rotate as necessary. 2. If the directional arrows are not present, installation can be verified by checking the location of the cross rail eyelets. When the location of the cross rail eyelets. When installed in the reverse direction, the cross rail eyelets will face the rear of the vehicle. Remove the cross rails and rotate as necessary. 3. Once the specified direction has been established, adjust the position of the cross rails, so that one cross rail is positioned at the rear most end of the vehicle. The other cross rail should then be positioned at approximately midpoint of the rear door glass. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagrams Engine Oil Level And Temperature Sensor Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 4868 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9483 C304 Part 1 Page 1587 DISCLAIMER Interior - Front Floor Carpet Is Wet Carpet: All Technical Service Bulletins Interior - Front Floor Carpet Is Wet TECHNICAL Bulletin No.: 03-08-57-004D Date: November 21, 2008 Subject: Front Floor Carpet Wet (Seal Top of "A" Pillar) Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2009 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-08-57-004C (Section 08 - Body and Accessories). Condition Some customers may comment that the front floor carpet is wet. Cause 1 Water may enter a hole in the seam sealer at the roof panel to upper "A" pillar post. In this case, the water enters the hole and leaks down the inside of the "A" pillar and ends up on the front floor. Refer to the illustration above. Cause 2 Water may enter the seam at the top of the "A" pillar. In this case, the water enters where the roof panel to upper "A" pillar meet and follows this seam under the windshield urethane. The water then drips onto the "A" pillar garnish molding and ends up on the floor. Refer to the illustration above. Cause 3 Page 6948 1. Install the transmission oil cooler lines to the vehicle. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick Connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Install a new retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Page 6208 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 262 Page 12994 7. Pass the feed wire (1) through the hinge (2), body pillar (3) and backing plate (4). 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire (1) while guiding the backing plate (2) into the inner structure. 10. Place the hinge (1) into position and hand tighten the 2 attaching bolts. Procedures Scuff Plate: Procedures Door Sill Plate Replacement - Front REMOVAL PROCEDURE 1. If removing the right sill plate, remove the right insulator panel. 2. Starting at the rear of the sill plate, use a flat-bladed tool in order to release the 5 retaining tabs. 3. If removing the left sill plate, remove the sill plate from the hood release handle. 4. Remove the sill plate from the door frame. 5. Remove any retaining tabs that remain attached to the door frame. INSTALLATION PROCEDURE 1. Ensure that all 5 retaining tabs are securely attached to the sill plate. 2. If installing the left sill plate, position the hood release handle through the sill plate. 3. Align the retaining tabs to the door frame slots. 4. Starting at the front of the sill plate, push down on the sill plate, seating the retaining tabs to the door frame. 5. If installing the right sill plate, install the right insulator panel. Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE Page 4581 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 3537 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 13644 Trim Panel Replacement - Rear Quarter Upper (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the cargo shade/cover. 2. Remove the screw that retains the trim panel to the body. 3. Remove the cargo net retaining knobs. 4. Remove the bolt that retains the seat belt upper guide to the body. 5. Remove the rear upper quarter trim panel from the vehicle. Installation Procedure 1. Install the rear upper quarter trim panel to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the rear seat belt upper guide to the body. Tighten the rear seat belt upper guide shoulder bolt to 70 N.m (52 lb ft). 4. Install the screw that retains the rear upper quarter trim panel to the body. Tighten the rear upper quarter trim panel screw to 2 N.m (18 lb in). 5. Install the cargo net retaining knobs. Page 1427 Conversion - English/Metric Page 4178 Electrical Symbols Part 4 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 12336 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 15727 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5890 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Locations Locations View Service and Repair Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement Removal Procedure Properly support the frame when you change the body mounts. If only one mount is changed, lower the entire side on which the mount in placed in order to provide clearance for the mount. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the mounts will be placed. 3. Remove the body mount bolt, retainer, and lower cushion (1) from the radiator support. 4. Remove the body mount bolts, retainers, and lower cushions (1) from the 5 other mount locations. 5. Lower the hoist enough in order to leave the body supported by the jack stands. 6. Remove the upper cushions (2) from the vehicle. Installation Procedure 1. Install the upper cushions (2) to the vehicle. 2. Raise the frame slightly on the hoist. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower cushions, retainers, and bolts to the 5 body mount locations. Specifications Heat Shield: Specifications Exhaust Manifold Heat Shield Nuts 44 inch lbs. Exhaust Manifold Heat Shield Stud 89 inch lbs. Catalytic Converter Heat Shield Bolts 62 inch lbs. Page 4724 Powertrain Control Module (PCM) C2 Part 1 Page 3861 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 403 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13964 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 13133 Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Removal Procedure 1. Remove the hood. 2. Using a grease pencil or other suitable marking device, mark the location of the hinge(s) (3) to the body. 3. Remove the bolts (2) that retain the hinge(s). 4. Remove the hinge(s) from the body. Installation Procedure 1. Position the hinge(s) (3) to the body as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) that retain the hinge(s) to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the hood. Page 2778 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 13942 Electrical Symbols Part 1 Page 1752 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 3241 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14971 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 11497 2. Remove the rear seat belt anchor nut (2) securing the seat belt (1) to the seat frame. 3. Pull the seat back cover and pad up to expose the seat belt bracket bolts. Refer to Seat Back Cover and Pad Replacement - Rear No.1 (Trailblazer, Envoy, Bravada) or Seat Back Cover and Pad Replacement - Rear No.1 (Trailblazer EXT, Envoy XL). 4. Remove the 2 bolts (2) securing the seat belt bracket (1) to the seat back frame. 5. Remove the nut (1) securing the retractor assembly (2) to the seat back frame. 6. Remove the retractor assembly. Page 9576 Disclaimer Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 15136 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 9885 Disclaimer Page 10173 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4567 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15918 Various symbols are used in order to describe different service operations. Page 8120 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13912 Disclaimer Page 6125 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 9896 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the park brake as firmly as possible, depress Auto Trans Shift Lock Control solenoid plunger and pull the shift lever to the L1 position. 15. Lift the console, disconnect the console wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (Trail Blazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (Except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward arid disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Brown/White wire. ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio in the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place it under the carpet to the area of the rear audio control and reposition the carpeting. Electrical - No Start/Multiple Systems Inoperative Driver/Vehicle Information Display: All Technical Service Bulletins Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Procedures Body Control Module: Procedures IMPORTANT: If the module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not property configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to Programming Theft Deterrent System Components in Theft Deterrent for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 8313 Page 4341 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 14397 6. Install the cover side flaps to the frame with the two push pins (1) from each side of the seat back. 7. Install the J-strips (2) on the bottom of the seat back cover (1). NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the rear seat belt (1) to the seat with the rear seat belt anchor nut (2). Tighten Tighten the rear seat belt anchor nut to 55 N.m (41 lb ft). A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12993 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the hinge pillar (3). 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3-mm (1/8-in) pilot hole at each location (1). 4. Drill a 13-mm (1/2-in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure DISCONNECTING THE NEGATIVE BATTERY CABLE FOR SERVICE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Record all preset and theft codes from the radio. 2. Turn the ignition switch to the LOCK position. 3. Verify that all the electrical components are off such as interior lights, all doors are closed, the underhood lamp, etc. 4. Remove the retaining bolt from the battery negative cable. 5. Remove the battery negative cable from the battery. 6. Position the battery negative cable away from any body ground. CONNECTING THE NEGATIVE BATTERY CABLE FOR SERVICE 1. Verify that all electrical components are off such as interior lights, all doors are closed, the underhood lamp, etc. 2. Clean corrosion from the battery negative cable using a metal brush. 3. Connect the battery negative cable to the battery. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the retaining bolt to the battery negative cable. Tighten Tighten the battery negative cable to 15 N.m (11 lb ft). Page 15996 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 6115 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 9190 Negative: Service and Repair Battery Negative Cable Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the bolt that secures the harness to the front wheelhouse panel (1). 3. Remove the bolt that secures the harness to the shock tower (2). 4. Remove the harness from the engine harness bracket. 5. Remove the bolt that secures the harness to the engine block. INSTALLATION PROCEDURE IMPORTANT: The negative battery cable must not be connected to the battery prior to the installation of the engine harness ground terminal to the engine block. - The negative battery cable must not be connected to the battery prior to the installation of the instrument panel harness and the engine harness to the powertrain control module. 1. Clip the harness to the engine harness bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt that secures the harness to the shock tower (2). Tighten Tighten the bolt to 10 N.m (89 lb in). Page 7799 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Page 6001 Equivalents - Decimal And Metric Part 1 Air Suspension Sensor - LR Page 7788 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5335 Conversion - English/Metric Page 8013 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 14538 Heated Seat Element - Front Passenger Cushion Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 14154 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With the aid of an assistant, remove the sunroof assembly from the vehicle and place on a clean, prepared surface. Refer to Sunroof Replacement 4. Remove the sunroof drive motor. 5. Remove the screw that retains the module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the module. 7. Remove the module from the mounting bracket. INSTALLATION PROCEDURE IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 1. Position the module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw that retains the module to the mounting bracket. Tighten Page 3410 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 8508 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 7. Install the motor/encoder to the transfer case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 8. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 9. Connect the motor/encoder electrical connector (1). 10. Install the fuel tank shield, if equipped. 11. Lower the vehicle. Page 15594 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15592 Electrical Symbols Part 8 Page 12155 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 9869 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 16062 Parts are currently available from GMSPO. Disclaimer Page 9356 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 15724 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 430 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 12958 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers (2) to the front door sealing weatherstrip located at the base of the pillar. 4. Close the door. Page 7881 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 5332 Equivalents - Decimal And Metric Part 1 Page 15771 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 6487 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 1412 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5241 Conversion - English/Metric Page 8970 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 70 Nm (52 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 3935 Accelerator Pedal Position (APP) Sensor A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: All Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 10528 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 4157 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 1857 Electrical Symbols Part 6 Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 5421 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 15994 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 14801 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 10552 7. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 8. Remove the ABS sensor from the wheel hub and bearing. 9. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 10. Remove the wheel hub and bearing from the steering knuckle. 11. Remove the splash shield from the steering knuckle. Installation Procedure Page 10707 Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Page 1497 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4790 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5877 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 7938 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13680 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 15482 Volt Meter Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. REAR WASH - 38 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 9724 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Diagrams Seat Heater Sensor: Diagrams Heated Seat Element - Driver Cushion Heated Seat Element And Thermistor Assembly - Driver Back Instruments - Erratic Speedometer Operation Speedometer Head: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 10969 Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core (2) from the HVAC module assembly (1). INSTALLATION PROCEDURE 1. Install the heater core (2) to the HVAC module assembly (1). 2. Install the heater core access cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater core access cover screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 3642 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Partially drain the cooling system. 2. Remove the upper radiator baffle. 3. Remove the vent inlet hose from the radiator. 4. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Install the vent inlet hose to the radiator. 3. Install the upper radiator baffle. 4. Fill the cooling system Page 232 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 7720 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 608 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 11316 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 11712 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 1987 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: Customer Interest Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 14323 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 5103 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESS The inflatable restraint wiring harnesses connect the inflators modules, SDM, deployment loops, and class 2 serial data together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing the SIR wiring harnesses follow the proper testing and wiring repair procedures. Page 9898 32. Reposition the rear electrical center through the carpet and reposition the carpet. 33. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 34. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 35. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in order, proceed to the next step. Otherwise, check your work. 36. Turn the key OFF. Remove the key. 37. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 38. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 39. Reinstall the rear electrical center cover. 40. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the attaching screws. 41. Reinstall the knee bolster (TrailBlazer). 42. Reinstall the left side closeout/insulator panel (TrailBlazer). 43. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 44. Reinstall the console to the vehicle and install the retainers. 45. Reinstall the shift boot and handle assembly. 46. Reinstall the console bin and retainers. 47. Reinstall the first lock pillar trim and carpet retainers to both door openings. 48. Position the driver's seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 49. Reinstall the SIR fuse # 18 in the underhood rear electrical center and close the hood. 50. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios Without Rear Audio Controls These vehicles use wiring harness P/N 15164934. 1. Remove the key from the lock cylinder. Page 11489 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - No. 2 Right Rear REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the right rear quarter trim panel. 3. Remove the rear seat belt lower anchor nut. 4. Remove the bolt that retains the seat belt retractor assembly to the body. 5. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt retractor assembly to the vehicle. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the right rear quarter trim panel. 4. Install the rear seat belt lower anchor nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat mounting nut to 45 N.m (33 lb ft). Page 14995 Conversion - English/Metric Page 6019 Electrical Symbols Part 3 Page 8813 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 10380 For vehicles repaired under warranty, use the table. Disclaimer Page 9348 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet - Console Auxiliary Power Outlet - Rear Page 14057 Memory Seat Module - Driver C2 Memory Seat Module - Driver C3 Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Tools Required J 25070Heat Gun Removal Procedure 1. Remove the molding from the vehicle using the following procedure: 1. Heat the door side molding using a J 25070. Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the door side molding from the panel surface using a flat-bladed tool. 2. Remove all adhesive from the body panel and the back of the door side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 3. Clean the body panel using Varnish Makers and Painters (VMP) naphtha. Installation Procedure 1. Ensure the painted body surface in the tape contact area is clean and dry. 2. Warm body panel with a heat lamp or heat gun if necessary, to a temperature between 18.8-41.1°C (66-100°F). 3. Remove the tape liner from the adhesive tape. Important: Do not touch the adhesive surface. 4. Ensure that the molding is aligned with the body panel. Press the door side molding to the body panel. 5. Hand roll the door side molding to the body in order to ensure proper adhesion. Page 2991 9. Remove the ignition control module. 10. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage the clips that hold the housing in place. 11. Disconnect the fuel injection harness electrical connector. 12. Loosen and remove the camshaft cover bolts. Page 9877 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 4323 Electrical Symbols Part 5 Page 10335 Stabilizer Link: Service and Repair Rear Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link retaining nuts. Notice: Do not pry on the stabilizer shaft link. Use care when removing or installing the stabilizer shaft link in order to avoid tearing or puncturing the stabilizer shaft link boot. Damage to the stabilizer shaft link boot will lead to damage to the stabilizer shaft link. 3. Disconnect the stabilizer shaft link from the frame. 4. Disconnect the stabilizer shaft link from the stabilizer shaft and remove the stabilizer shaft link. Installation Procedure 1. Connect the stabilizer shaft link to the stabilizer shaft and to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the stabilizer shaft link retaining nuts. Tighten the stabilizer shaft nuts to 100 Nm (74 ft. lbs.). 3. Lower the vehicle. Page 1405 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 14244 Memory Seat Module - Passenger C3 Page 14775 Electrical Symbols Part 4 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Service and Repair Rear Door Limiter: Service and Repair REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the front half of the water deflector in order to expose the door access hole. 3. Remove the 2 bolts that retain the check link to the pillar. 4. Remove the rubber dust boot from the check link in order to gain access to the door retaining nuts. Page 5293 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 14798 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 4491 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 8653 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 13620 10. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. 11. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 12. Rotate and clip the sunshade to the inboard retainer. 13. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 14. Install the front assist handle to the roof panel. 15. Install the windshield garnish molding. 16. Install the center pillar trim panel. 17. Return the bucket seat to an upright position. Page 7039 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1542 Various symbols are used in order to describe different service operations. Page 15955 Headlamp Relay: Service and Repair HEADLAMP DRIVER MODULE (HDM) RELAY REPLACEMENT TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the headlamp driver module (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the headlamp driver module (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 8780 Page 15725 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 11249 10. Disconnect the discriminating sensor (2) electrical connector. 11. Remove the discriminating sensor from the vehicle. INSTALLATION PROCEDURE 1. Position the discriminating sensor assembly above the front bumper. 2. Connect the discriminating sensor (2) electrical connector. 3. Install the connector-position assurance (CPA) to the discriminating sensor electrical connector. 4. Install the retaining bolts and protective cover (1) to the discriminating sensor. 5. Position the discriminating sensor assembly to the frame (1). NOTE: Refer to Fastener Notice in Service Precautions. Page 3402 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 14601 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14403 1. Remove the 3 seat switch bezel screws. 2. Remove the 4 nuts that retain the seat pan to the seat adjuster assembly. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. 4. Release the J strips (1, 3) on each side of the seat cushion. 5. Release the front/rear J strips (2,4). 6. Remove the SIR electrical harness (2) from the seat pan. Page 1739 Electrical Symbols Part 5 Exhaust - Exhaust Noise/Leak Exhaust Manifold Gasket: Customer Interest Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 10285 Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Rear Steering Gear Crossmember Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front steering gear crossmember rear mounting bolts. 3. Remove the rear steering gear crossmember mounting bolts. 4. Remove the rear steering gear crossmember from the vehicle. Installation Procedure 1. Install the rear steering gear crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear steering gear crossmember mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the front steering gear crossmember rear mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 4. Lower the vehicle. Page 11908 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 7861 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 7. Install the motor/encoder to the transfer case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 8. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 9. Connect the motor/encoder electrical connector (1). 10. Install the fuel tank shield, if equipped. 11. Lower the vehicle. Page 12171 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Service Precautions Vehicle Lifting: Service Precautions Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. - Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 5142 Electrical Symbols Part 5 Page 12425 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 4085 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 8868 Brake Caliper: Technical Service Bulletins Brakes - Rear Caliper Mounting Bolt Torque Revision Bulletin No.: 04-05-23-003 Date: April 22, 2004 SERVICE MANUAL UPDATE Subject: Revised Rear Brake Caliper Bracket Mounting Bolt Fastener Specification Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2004 Isuzu Ascender This bulletin is being issued to revise the fastener tightening specification for the rear brake caliper bracket mounting bolt in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The revised specification is as follows: Rear Brake Caliper Bracket Mounting Bolt - 200 N.m (147 lb ft) Disclaimer Page 4505 Accelerator Pedal Position (APP) Sensor Page 1677 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 4609 Electrical Symbols Part 3 Page 1319 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1978 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Radiator Cooling Fan Motor: All Technical Service Bulletins Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Bulletin No.: 05-06-02-012B Date: October 19, 2006 TECHNICAL Subject: Service Engine Soon (SES) or Check Engine Light On, DTC P0480/P0526/P1481/P1484 Set (Replace Engine Cooling Fan Wiring Harness) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2005-2006 GMC Envoy Denali, Envoy XL Denali 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add DTC P1484. Please discard Corporate Bulletin Number 05-06-02-012A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the Service Engine Soon (SES) or Check Engine light is illuminated. This condition may be intermittent and upon investigation, the technician may find either DTC P0480, P0526, P1481 or P1484 set. Cause This condition may be caused by the cooling fan harness chaffing against the plastic guide it routes through. This contact may damage the insulation of the wires enclosed in that harness. Correction Replace the engine cooling fan harness using the procedure listed below. Remove the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Place the cooling fan assembly on a bench. Disconnect the harness electrical connector from the cooling fan clutch. Remove the harness from the plastic guide while feeding the wires out of the slot. Before installing the new harness, wrap the affected area on the wires with electrical tape to keep the protective sleeve in place. Be sure to keep the tape Page 178 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 15699 Center Mounted Brake Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 1793 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 9652 Fuse Block - Underhood C4 Page 269 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 15689 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 6133 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 1468 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Rearview Mirrors (Outside) - Uncommanded Movement Door Module: All Technical Service Bulletins Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 12567 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 5517 Page 11111 Locations View - HVAC Systems - Automatic Page 15611 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12277 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 5772 Electrical Symbols Part 6 Page 117 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 766 Conversion - English/Metric Page 14621 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. HVAC Systems - Manual Locations View - HVAC Systems - Manual Page 8657 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Front Motor (W/Memory Seat) Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 2176 Page 5458 Electrical Symbols Part 6 Page 9856 43. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 44. Turn the key OFF. Remove the key. 45. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 46. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 47. Reinstall the rear electrical center cover. 48. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 49. Reinstall the knee bolster (TrailBlazer). 50. Reinstall the closeout/insulator panel (TrailBlazer). 51. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 52. Reinstall the console to the vehicle and install the retainers. 53. Reinstall the shift boot and handle assembly. 54. Reinstall the console bin and retainers. 55. Reinstall the first lock pillar trim and carpet retainers to both door openings. 56. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 57. Install the IP upper trim panel and windshield pillar moldings. 58. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 59. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios With Rear Audio Controls These vehicles use wiring harness P/N 15164933. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. Page 11687 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9461 C203 Fuse Block - Rear Fuse Block: Diagrams Fuse Block - Rear Fuse Block - Rear C1 Part 1 Page 9854 58. Install the IP upper trim panel and windshield pillar moldings. 59. Reinstall the SIR fuse #18 in the underhood electrical center and close the hood. 60. Connect the Tech 2(R) and clear codes. Bose(R) Premium Sound Without Rear Audio Controls These vehicles use wiring harness P/N 15164931, which you will modify slightly by cutting some unused wires. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove the shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconnect the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). 22. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. Important: Page 164 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 10479 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Recall - Front Seat Belt Retractor Defect Technical Service Bulletin # 04037 Date: 040601 Recall - Front Seat Belt Retractor Defect File In Section: Product Recalls Bulletin No.: 04037 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: FRONT SEAT BELT RETRACTOR NONCOMPLIANCE MODELS: 2002 CHEVROLET TRAILBLAZER 2002 GMC ENVOY 2002 OLDSMOBILE BRAVADA Since the inspection procedure in this recall can be performed quickly and easily, and to reduce the inconvenience to the customer, when a customer brings their vehicle into your dealership for this recall, if at all possible, have this inspection performed on the vehicle immediately so that the customer does not have to leave their vehicle at the dealership. If you confirm proper retractor lockup, GM recommends that you demonstrate to the customer that the retractor locks properly. CONDITION General Motors has decided that certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies. These vehicles have a condition where one of the two sensors in the driver's and front passenger's seat belt retractors may be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as during heavy braking, may not operate as intended. If this were to occur, the seat belt may not restrain the occupant as intended during a crash, and could result in injury to the occupant. CORRECTION Dealers are to inspect the driver and front passenger seat belt retractors, and replace them if necessary. Since the inspection is easy to perform, and to reduce customer inconvenience, customers will be sent an inspection procedure with instructions to contact their dealer if a seat belt retractor does not lock while performing the inspection. However, if they desire, they can take their vehicle to their dealer for the inspection. VEHICLES INVOLVED Involved are certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Steering Wheel - Removal Procedure Revision Steering Wheel: Technical Service Bulletins Steering Wheel - Removal Procedure Revision Bulletin No.: 03-02-35-006 Date: December 02, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Replacement Procedure Models: 2002 Cadillac Escalade, Escalade EXT 2001-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Express, SSR 2001-2002 GMC Sierra, Yukon, Yukon Denali, Yukon XL 2002-2003 GMC Envoy, Envoy XL 2003 GMC Savana 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 2003 Isuzu Ascender This bulletin is being issued to revise the Steering Wheel Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 5108 Conversion - English/Metric Page 2198 Electrical Symbols Part 7 Page 14260 Seat Rear Vertical Motor - Driver/Passenger Page 14507 Position Sensor - Recline Motor (W/Memory Seat) Page 8597 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13877 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 13027 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Page 1091 Position Sensor - Rear Motor (W/Memory Seat) Page 12333 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 8690 Page 7816 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Data Link Connector (DLC) Data Link Connector (DLC) Page 5294 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 6697 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 15516 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 3279 2. Install the valve spring and the valve spring retainer. 3. Use the J 44228 and compress the valve springs. 4. Install the valve keys. 5. Remove the J 44228. Page 10205 Steering Wheel: Description and Operation STEERING COLUMN AND WHEEL The Steering wheel and columns are designed to absorb energy when driver contact is made with the steering wheel or inflated air bag. In a frontal collision the driver may come in contact with the steering wheel directly or load the steering wheel and column through the inflated air bag. When the driver applies load to the air bag or the steering wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damages after a collision. Page 14943 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14983 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 15722 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, the SIR sensor must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 5048 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 808 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9880 For vehicles repaired under warranty, use the table. Disclaimer Page 5050 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: All Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 2924 13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. Cylinder Bore Sleeve Installation Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve (117), PIN 88984239, onto the cylinder block. 2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1), which is part of EN 45680-400,over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117). Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401(1). 4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten Tighten the 4 attachment bolts to 15 Nm (11 lb ft). Page 8751 Page 8919 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 8852 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Locations Locations View Page 1261 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 8588 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13564 16. Leaving the mechanic's wire positioned behind the IP, remove the headliner harness from the mechanics wire. 17. Remove the front and rear overhead console, if equipped. 18. Remove the video display, if equipped. 19. Remove the sunshades from the headliner. 20. Remove the sunshade retainer clips. 21. Remove the third row seats. 22. Remove the second row seats. 23. Remove the left/right front body side window garnish molding. 24. Remove the left/right rear body side window garnish molding. 25. Remove the lift gate door sill plate. 26. Remove the left rear quarter lower trim panel. 27. Remove the right rear quarter lower trim panel. 28. Remove the bolts from the cargo tie-down loops. 29. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 30. Loosen the three bolts that secure the jack carrier to the vehicle. 31. Remove the carpet from around the wheel stud. 32. Remove the body electrical block. 33. Peel the carpet forward and up over the front seats. Note that the carpet hooks around the wheel house panel stud. Page 8979 Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake hose bolt from the rear brake caliper. 4. Plug the opening of the brake hose in order to prevent excessive brake fluid loss and contamination. Important: Discard the metal (copper) gaskets. DO NOT reuse metal (copper) gaskets, replace them. 5. Remove the metal (copper) gaskets from the brake hose bolt. 6. Remove the rear brake caliper mounting bolts. Page 12367 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 5881 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5957 Equivalents - Decimal And Metric Part 1 Page 2394 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The tender to radiator support rod will be removed as part of the radiator support cover. 1. Remove the radiator support cover. 2. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator. 3. Remove the air cleaner element (1) by grasping the filter and removing it from the air cleaner outlet duct (2) with a twisting and pulling motion. 4. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 6204 Lighting - Tail Lamp(s) Inoperative Tail Lamp Socket: Customer Interest Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 3221 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6227 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 3616 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 9070 Installation Procedure 1. Install the gasket and the vacuum booster assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vacuum booster mounting nuts on the vacuum booster. ^ Tighten the vacuum booster mounting nuts to 40 Nm (30 ft. lbs.). 3. Position the stop lamp switch (1) on the pushrod (2) and install on the brake pedal pin . 4. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. 5. Install the left closeout/insulator panel. 6. Install the vacuum hose to the vacuum booster and to the engine. 7. Install the master cylinder. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 133 Page 712 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9583 WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 40. Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. 41. Reposition the rear electrical center through the carpet and reposition the carpet. 42. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 43. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 44. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 45. Turn the key OFF. Remove the key. 46. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 47. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 48. Reinstall the rear electrical center cover. 49. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 50. Reinstall the knee bolster (TrailBlazer). 51. Reinstall the closeout/insulator panel (TrailBlazer). 52. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 53. Reinstall the console to the vehicle and install the retainers. 54. Reinstall the shift boot and handle assembly. 55. Reinstall the console bin and retainers. 56. Reinstall the first lock pillar trim and carpet retainers to both door openings. 57. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). Page 8295 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 5365 Canister Purge Solenoid: Description and Operation EVAP Vent Valve The EVAP vent valve (1) controls fresh airflow into the EVAP canister. The EVAP vent valve is a normally open valve. The PCM will command the valve closed during some EVAP tests, allowing the system to be tested for leaks. Page 1058 Locations View Page 5607 5. Connect the fuel feed and return pipes (1, 2) to the fuel rail. 6. Connect the fuel injector electrical connectors. 7. Connect the fuel pressure regulator vacuum line. 8. Install the intake manifold. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition, with the engine OFF for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. Service and Repair Evaporative System Service Port: Service and Repair EVAP Service Port The EVAP service port is located in the EVAP purge pipe between the EVAP purge valve and the EVAP canister. The service port is identified by a green colored cap. Page 2898 Bolt Extractor Tool Kit Part Number EN-47702 The bolt extractor kit EN-47702 provides the following components to assist in removal of the broken bolt segment: 1. One 5/32" reverse twist drill - part number EN-47702-6 2. One double-ended drill pilot insert - part number EN-47702-1 (ensures a straight drilling procedure) 3. Drill pilot inserts for larger diameter heads or main cap bolts - part number EN-47702-2 (ensure a straight drilling procedure) 4. Bolt extraction # 3 EZ out - part number EN-47702-3 (after the drilling procedure) 5. Bottom tap (M11 X 2) - part number EN-47702-5 (for the head bolts to chase the threads after the completion of bolt removal) 6. Bottom tap (M10 X 1.5) - part number EN-47702-4 (for the main bolts to chase the threads after the completion of bolt removal) Disclaimer Page 6331 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 9315 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 11825 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 3979 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 4288 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 11423 6. Remove the seat belt anchor nut. 7. Remove the screw that attaches the seat belt bezel to the seat back. 8. Remove the seat belt material from the bezel. 9. Release the J-strips (1, 4) across the bottom of the seat back cover. 10. Remove the push pins (3) securing the seat cover (2) to the seat frame. 11. Remove the head restraint. 12. Using a flat-bladed tool, carefully disengage the plastic strips or channels that retain the seat back cover to the side impact airbag module. Page 11393 Disclaimer Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 3621 Various symbols are used in order to describe different service operations. Page 14362 7. Remove the release latch knob. 8. Remove the screw that retains the seat back latch release bezel to the seat back. 9. Release the J strips on the bottom of the seat back frame. 10. Release the hook and loop retaining strips at the bottom of the seat back. 11. Remove 3 push-pins from the bottom of the seat back. Page 1531 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 10111 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Instruments - Erratic Speedometer Operation Speedometer Head: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 15358 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Page 14400 7. Pull the seat back cover up by releasing the hook and loop fastener strips (2). 8. Remove the hog rings (1) securing the cover to the pad. 9. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 10. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. 11. Remove the cover and pad from the seat back frame. INSTALLATION PROCEDURE Page 11703 Driver/Vehicle Information Display: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 6681 Page 5426 Fuel: Specifications Gasoline Octane Regular Unleaded Gasoline 87 Octane or Higher It is recommended that gasoline meet specifications which If the octane is less then 87, you may get a heavy knocking were developed by the American Automobile Manufacturers noise while driving. If it is bad enough, it can damage your Association and endorsed by the Canadian Vehicle engine. Manufacturers Association. Page 789 Electrical Symbols Part 3 Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 13058 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 3 fasteners that retain the latch to the door. Tighten the fasteners to 10.0 N.m (22 lb in). 5. Install the outside handle lock rod to the outside handle. 6. Install the inside door handle lock rod to the latch. 7. Install the water deflector. 8. Install the door trim panel. Page 2056 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 10293 3. Connect the upper control arm to the steering knuckle. 4. Install upper control arm pinch bolt and nut. Tighten the upper control arm pinch bolt to 40 Nm (30 ft. lbs.). 5. Install the brake hose bracket to the steering knuckle. 6. Install the brake hose bracket retaining bolts. Tighten the brake hose bracket retaining bolts to 10 Nm (7 ft. lbs.). 7. Install the outer tie rod to the steering knuckle. 8. Install the new outer tie rod retaining nut. Tighten the outer tie rod retaining nut to 45 Nm (33 ft. lbs.). 9. Install the wheel hub and bearing. 10. Install the tire and wheel. 11. Lower the vehicle. Page 984 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 15203 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 7539 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 2316 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 3308 Engine Oil Pressure (EOP) Switch Page 4611 Electrical Symbols Part 5 Page 115 Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Page 5089 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8423 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). Page 12446 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 9935 Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 8843 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 9851 For vehicles repaired under warranty use the table shown. DISCLAIMER Bose(R) Premium Sound With Rear Audio Controls These vehicles use wiring harness P/N 15164931. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconned the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). Page 10060 Power Steering Pump: Service and Repair Power Steering Reservoir Replacement - Off Vehicle (CB Series) Power Steering Reservoir Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or the hydraulic pump housing (1). Discard the O-ring seal. Assembly Procedure 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Page 469 Memory Seat Module - Passenger C2 Page 13749 Door Lock Actuator - RR Page 7158 Page 15454 Electrical Symbols Part 7 Page 5941 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 14439 4. Install the seat cushion panel on the pad and cover. 5. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 6. Install the pull handle assembly (1). Notice: Refer to Fastener Notice in Service Precautions. 7. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). Tighten the seat cushion bolts to 11 N.m (97 lb in). Seat Cushion Panel Replacement - Rear No. 2 Seat Cushion Panel Replacement - Rear No. 2 Removal Procedure 1. Remove the two rear seat cushion bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the seat cushion assembly. 3. Remove the pull handle (1). 4. Remove the J-strips (2) securing the seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. Installation Procedure Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 1295 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 14622 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 7520 Disclaimer Propshaft Speed Sensor - Front Page 3915 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10022 Power Steering Line/Hose: Service and Repair Power Steering Hose Assembly Replacement Tools Required ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise the vehicle and support with suitable safety stands. Refer to Vehicle Lifting. 2. Install a drain pan under the vehicle. 3. Remove the power steering hose assembly to the power steering gear retaining bolt. 4. Disconnect the power steering hose assembly from the power steering gear. 5. Remove the power steering return hose and power steering cooler hose from the power steering cooler. 6. Lower the vehicle. 7. Disconnect the fuse block wiring harnesses from the wiring loops. 8. Remove the fuse block. 9. Remove the battery tray. Page 8972 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul- Front ^ Tools Required J 8092 Driver Handle - J 43885 Boot Seal Installer Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure Page 11193 Ambient Light/Sunload Sensor Assembly Page 12977 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Disconnect the electrical connector from the regulator motor. 6. Loosen the upper 2 bolts that retain the regulator assembly to the door. 7. Remove the remaining 3 bolts that retain the window regulator assembly and the motor to the door. 8. Lift the regulator assembly upward in order to release the upper 2 bolts. 9. Rotate the upper portion of the regulator assembly forward. 10. Beginning with the lower portion, remove the regulator assembly through the door opening. 11. Place the regulator assembly on a prepared surface. 12. Remove the upper 2 bolts from the regulator assembly. Installation Procedure 1. Partially install the upper 2 bolts to the regulator assembly. 2. Beginning with the upper portion, install the regulator assembly through the door opening in a semi-horizontal position. 3. Position the regulator assembly fully forward into the door cavity. 4. Rotate the regulator assembly to a vertical position. 5. Lower and hang the regulator assembly onto the door sheet metal using the upper 2 bolts that were previously installed. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolt that retains the motor to the door. Tighten bolts to 9 N.m (80 lb in). 7. Install the remaining bolts that retain the regulator assembly to the door. Tighten bolts to 10 N.m (88 lb in). 8. Connect the electrical connector to the regulator motor. 9. Install the side door window. 10. Install the water deflector. 11. Install the speaker. 12. Install the door trim panel. Page 15455 Electrical Symbols Part 8 Locations Locations View Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 15398 Electrical Symbols Part 7 Page 4694 Electrical Symbols Part 6 Page 5885 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 11552 Disclaimer Page 276 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 12346 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 14242 Power Seat Control Module: Diagrams Memory Seat Module - Passenger Memory Seat Module - Passenger C1 Page 3253 9. Wipe off any excess material from the bottom of the oil pan sealing area (1). 10. Install the fly wheel and secure with the bolts. ^ Tighten the fly wheel bolts in sequence to 25 Nm (18 ft. lbs.). 11. Use the J 36660-A to tighten the bolts an additional 50 degrees. 12. Install the transmission. Page 15686 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 1153 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Page 5264 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 11966 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 9787 C201 Part 1 Page 12445 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Fuse Block - Rear Locations View Page 12815 Condition Some customers may comment that the front fascia on the vehicle appears to be loose. This condition may be noticed while the customer is washing the vehicle. Correction Replace the front fascia pencil braces using the following service procedure. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 744862). 2. Remove the lower push-in retainer and the upper bolt from both the right and left front fascia pencil braces. 3. Remove the right and left front fascia pencil braces. 4. Replace the front fascia pencil braces with new pencil braces. Refer to the applicable part numbers listed below. 5. Install and "finger tighten" the upper brace bolts on both sides. 6. Install the lower brace push in retainers on both sides. Tighten Tighten the upper brace bolts to 10 N.m (89 lb in). 7. Lower the vehicle. Parts Information Parts are expected to be available 8-8-2002 from GMSPO. Page 15892 Electrical Symbols Part 7 Page 8266 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 15354 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12364 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 701 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. Page 7441 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-04-19-002B Date: 040404 Page 13401 Tighten the bolts to 80 N.m (59 lb ft). 4. Install the lower cushion, retainer, and bolt to the radiator support. Tighten the bolts to 80 N.m (59 lb ft). Page 12547 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 8605 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 5928 Electrical Symbols Part 2 Page 8310 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: All Technical Service Bulletins Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure. Page 12568 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 10629 Locations View - HVAC Systems - Manual Page 1214 Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Page 4266 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 10215 Tie Rod End: Service and Repair Tie Rod End Replacement - Inner Tie Rod Replacement - Inner Tools Required ^ J34028 Inner Tie Rod Wrench Removal Procedure Important: The boot and retaining clamps must be replaced when replacing the inner tie rod. 1. Remove the rack and pinion boot. 2. Place the gear in a vise. Important: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. This could result in damage to both the pinion and the steering gear. 3. Separate the shock dampener (4) from inner tie rod assembly (2). 4. Slide the shock dampener back on the rack (3). Important: The pipe wrench must be placed at the valve end of the steering gear (1) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (1). 5. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). 6. Place a wrench on the flats of the inner tie rod housing (2). 7. Rotate the inner tie rod housing (2) counterclockwise until the inner tie rod separates from the rack (3). 8. At the other gear end, separate the shock dampener (3) from inner tie rod assembly (2). 9. Slide the shock dampener (3) back on the rack (4). Important: The pipe wrench must be placed at the valve end of the steering gear (5). Placing the pipe wrench in any other location will cause damage to the steering gear (5). Page 1554 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 4046 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The FTP sensor mounts in the top of the fuel tank-sending unit. The PCM provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the PCM that can vary between 0.1-4.9 volts. As fuel tank pressure increases, FTP sensor voltage decreases (high pressure = low voltage). As fuel tank pressure decreases, FTP voltage increases (low pressure or vacuum = high voltage). Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 14477 8. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 9. Remove the seat back. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 2. Install the seat back. Page 11936 Page 12399 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 14833 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 385 Door Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 8209 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Specifications Valve Seat: Specifications Valve Seat Runout - Maximum 0.002 inch Valve Face Runout - Maximum 0.0015 inch Page 1463 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 9228 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6120 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12344 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 7481 Page 5170 Various symbols are used in order to describe different service operations. Page 13466 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 9182 Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 2714 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 3656 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Liftgate - License Plate Housing Paint Rubs Through License Plate Frame: All Technical Service Bulletins Liftgate - License Plate Housing Paint Rubs Through File In Section: 08 - Body and Accessories Bulletin No.: 02-08-66-004 Date: April, 2002 TECHNICAL Subject: Paint Rub Through on Liftgate Around Edge of License Plate Housing/Pocket (Install Insulating Seal/Gasket) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the paint on the liftgate around the edges of the license plate housing or pocket appears to be rubbing through or wearing off. Cause Changes in temperature may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing comes in contact with or rubs against the paint surface on the liftgate. Correction Remove the license plate housing from the liftgate. Refer to the License Plate Pocket Replacement procedure in the Service Manual (SI2000 Document ID # 740995). Install an insulating perimeter seal or gasket on the backside edge of the housing as shown. When properly installed, the seal (1) will start at one side of the liftgate release handle (2) and go completely around the housing stopping at the other side of the handle. Do NOT attempt to install the seal on the liftgate housing directly below the release handle. Once installed, it may be necessary to trim off any excess seal material. Parts Information Parts are expected to be available 4-22-2002 from GMSPO. Warranty Information Page 9069 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure 1. Apply the parking brake. 2. Remove the master cylinder. 3. Disconnect the vacuum hose from the vacuum booster and from the engine. 4. Remove the left closeout/insulator panel. 5. Remove the pushrod retainer (3) from the brake pedal pin (4). 6. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 7. Remove the vacuum booster mounting nuts. 8. Remove the vacuum booster assembly. 9. Remove the gasket. Engine - Balancer Hub Application/Service Precaution Harmonic Balancer - Crankshaft Pulley: Technical Service Bulletins Engine - Balancer Hub Application/Service Precaution Bulletin No.: 04-06-01-003 Date: March 01, 2004 INFORMATION Subject: Information on 2nd Design Balancer Hub Models: 2004 Buick Rainier 2003-2004 Chevrolet Trailblazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Envoy XUV 2003-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Depending on the vehicle and assembly plant, during the late 2003 model year or early 2004 model year, the design of the engine balancer hub was changed. Care should be exercised when servicing any of the vehicles listed above. The 1st design hub is straight and smooth. The 2nd design balancer hub has a step machined on it. The inside diameter of the seal has changed, but the outside diameter has not. It is possible to install either seal into the front cover, however, the incorrect seal will leak between the seal lip and hub of the damper. Note: Be sure to service with the proper combination of balancer, seal and washer. Mixing combinations could lead to an excessive engine oil leak and possible engine failure. Page 7815 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 7410 16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 17. thoroughly degrease all of the CV joint parts. 18. Check the outer CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts. 19. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure Important: Replace the joint assembly if necessary. 1. Inspect all of the parts for unusual wear, cracks, or other damage. 2. Put a light coat of the recommended grease on the inner and the outer race grooves. 3. Insert the inner race (1) into the cage (2) by rotating the inner race downward. 4. Hold the inner race (1) at 90 degrees to the centerline of the cage. 5. Align the lands of the inner race (2) with the windows of the cage (3). 6. Rotate the inner race downward to insert the inner race into the cage. 7. Insert the cage (4) and inner race into the outer race (1). Page 13640 1. Install the auxiliary power outlet to the trim panel. 2. Position the trim panel to the vehicle. 3. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 4. Index the locating tabs on the trim panel to the holes in the body. 5. Connect the wiring harness connector to the auxiliary power outlet. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the five screws that the retain the rear quarter trim panel to the body. Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 7. Install the seat belt lower anchor. Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 8. Install the left rear door sill panel. 9. Install the liftgate sill plate. 10. Install the left body side window forward garnish molding. 11. Install the left body side window rear garnish molding. 12. Return the third row seats to the upright position. 13. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Left (TrailBlazer, Envoy, Bravada) Trim Panel Replacement - Rear Quarter - Left (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the cargo shade/cover. 2. Remove the left body side upper trim panel. 3. Remove the liftgate sill plate. 4. Remove the left rear door sill panel. Page 1152 Antenna Extension Cable Replacement Antenna Cable: Service and Repair Antenna Extension Cable Replacement REMOVAL PROCEDURE 1. Remove the inflatable restraint instrument panel (IP) module. 2. Disconnect the antenna cable (2) from the radio extension cable. IMPORTANT: Note the location of the radio extension cable before removal. 3. Remove the cable attachments (1) from the IP support bars. 4. Reach through the IP compartment to disconnect the antenna cable from the radio. 5. Remove the radio extension cable from the vehicle. INSTALLATION PROCEDURE Page 2728 Disclaimer Page 4858 Electrical Symbols Part 2 Page 11726 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 14975 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Part 1 Turn Signal/Multifunction Switch C1 Part 2 Page 10498 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 11203 ^ Visually inspect the steering shaft for sheared injected plastic (1). If the steering shaft shows sheared plastic, replace the steering shaft. ^ Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked. Using a dial indicator at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.0625 inch). Page 10714 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Left REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Page 5052 Equivalents - Decimal And Metric Part 1 Page 6682 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 23458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 7950 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 432 Disclaimer Page 12554 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 10763 Auxiliary Blower Motor: Service and Repair TrailBlazer EXT and the Envoy XL. BLOWER MOTOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the retaining bolts (5) from the HVAC module-auxiliary (1). 3. Remove the retaining nuts (4) from the HVAC module-auxiliary (1) under the vehicle. 4. Disconnect the electrical connectors (3,4). 5. Remove the blower motor screws. 6. Remove the blower motor (1) from the HVAC module-auxiliary (2). INSTALLATION PROCEDURE Page 7771 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 1310 Electrical Symbols Part 5 Page 14152 Locations View Page 7509 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Page 15196 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Cigarette Lighter - Inoperative Cigarette Lighter: Customer Interest Cigarette Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-016 Date: November, 2001 TECHNICAL Subject: Cigarette Lighter May Be Inoperative (Install New Lighter Element) Models: 2002 Buick LeSabre, Park Avenue, Rendezvous 2002 Cadillac DeVille, Seville 2001-2002 Chevrolet Cavalier 2002 Chevrolet Impala, Malibu 2002 Chevrolet Trans Sport (Export Only) 2002 Oldsmobile Alero, Aurora 2001-2002 Pontiac Sunfire 2002 Pontiac Bonneville, Grand Am 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Chevrolet and GMC 6-7H C-Series Conventional Medium Duty Models 2001-2002 Oldsmobile Bravada Condition Some customers may comment that the cigarette lighter is inoperative. Cause During the 2001 model year, a new style cigarette lighter element was put into production. Under certain conditions, when pushed in firmly, the cigarette lighter element may short to ground inside the receptacle. This condition may result in a blown fuse. Correction Install a new cigarette lighter element, P/N 11516140. Replace the fuse for the cigarette lighter, if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6171 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 11401 1. Install the seat belt buckle assembly onto the seat. 2. Install a new grommet (1). 3. Install the seat assembly in the vehicle. Page 6107 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 14855 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 5757 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 652 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 8709 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Page 3594 Electrical Symbols Part 6 Page 1815 Crankshaft Position (CKP) Sensor Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 8873 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. Locations Locations View OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 9471 C312 Part 2 C313 Page 1413 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Locations Locations View - HVAC Systems - Manual Page 6488 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15625 Stop Lamp Switch Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. Page 13052 Page 8366 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Steering Gear Crossmember Replacement - Front Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Front Steering Gear Crossmember Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. 4. Remove the lower control arm to frame mounting bolts. 5. Remove the steering gear crossmember mounting bolts. 6. Remove the steering gear crossmember. Installation Procedure 1. Install the steering gear crossmember. Page 6442 Page 3808 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. Page 4084 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 1289 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 13864 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 4081 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 729 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10820 For vehicles repaired under warranty, use the table shown. DISCLAIMER Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 9379 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 2361 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Diagrams Engine Oil Level And Temperature Sensor Page 9585 With the new harness stretched out on a work surface, you will find two multi-terminal breakouts midway down the harness. You will need to trim these wire breakouts from the harness by cutting the four wires below at both locations as close to the taped portion of the harness as possible. ^ The Brown wire ^ The Brown/White wire ^ The Black wire ^ The Blue wire What you will end up with is a new harness with two green connectors on one end and four terminals on the other end. 27. Position the new radio speaker wiring harness to the vehicle. The small green connectors go to the upper IP speakers. 28. With the green connectors in hand, insert the new wiring harness from under the IP up to the radio area of the IP where the radio is normally positioned. 29. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 30. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 31. Disconnect the mechanics wire from the speaker wires. Connect the speaker wires to the speaker and fasten the speaker to the IP. 32. Repeat the last three steps for the right speaker. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting. 35. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 36. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 37. Route the new harness under the carpet from the rear of the console to the 8-way connector. 38. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 39. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 40. Reposition the rear electrical center through the carpet and reposition the carpet. 41. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 42. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). Page 12296 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 4265 Conversion - English/Metric Page 1643 Electrical Symbols Part 7 Page 5735 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 4598 Engine Coolant Temperature (ECT) Sensor Page 3898 Electrical Symbols Part 3 Page 8138 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 1775 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). A/T - Fluid Oil Cooler Flush Transmission Cooler: All Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 6339 For vehicles repaired under warranty, use the table. Disclaimer Page 9059 11. Install the brake caliper and mounting bracket. 12. Install the tire and wheel. 13. Lower the vehicle. Refer to Vehicle Lifting. A/C - Slow to Cool in Hot/Humid Conditions Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 3923 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15112 Electrical Symbols Part 3 Page 5037 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 7234 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 5703 Various symbols are used in order to describe different service operations. Page 15237 Miniwedge (Door Jamb Switch) - Liftgate Page 4312 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 14063 Power Seat Control Module: Description and Operation MEMORY SEAT MODULE (DSM) Battery positive voltage is supplied through the seat circuit breaker to the DSM. In response to a valid manual or memory switch command, the DSM will apply power and ground to the selected motors within 150 ms. To limit peak power, DSM restricts the number of motors that can be turned on simultaneously to three motors. If the module detects all four switches at the same time, DSM turns on three seat adjusters: horizontal, front, and rear. If the user continues to hold all four switches, the DSM actuates the fourth motor only after one of the first three motors has reached its end motion. For a memory recall operation, the DSM first moves the horizontal, front, and rear motors first. If all four switches are still activated, DSM actuate the recline motor only when one of the seat adjusters has reached its end motion. In order to conserve battery power, the DSM enters automatic standby mode whenever the unit has been inactive for 16 seconds. In the standby mode, the DSM stores memory settings so that when it is awake again it knows where the seat is set. Page 1770 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 13026 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Page 10656 10. Verify that no DTCs have set as current DTCs. Primary HVAC When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a re-calibration process. When installing the HVAC control module be sure to perform the following: 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the HVAC control module. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. Wait 40 seconds for the HVAC control module to re-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing the motor assembly it will be necessary to allow the HVAC control module to perform a re-calibration process. When installing the motor assembly be sure to perform one of the following: Preferred Method (W/ Scan Tool) 1. Clear all DTCs 2. Place the ignition switch in the OFF position. 3. Install the motor assembly. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. With the scan tool, initiate the Motor Re-calibration feature of the HVAC module Special Functions menu. 7. Verify that no DTCs have set as current DTCs. Alternate Method (W/O Scan Tool) 1. Clear all DTCs 2. Place the ignition switch to the OFF position. 3. Disconnect the scan tool. 4. Install the motor assembly. 5. Re-connect all previously disconnected components. 6. Remove the HVAC B fuse for a minimum of 10 seconds. 7. Re-install the HVAC B fuse. 8. Place the ignition switch in the RUN position. 9. Wait 40 seconds for the HVAC control module to re-calibrate. 10. Verify that no DTCs have set as current DTCs. Recirculation Actuator REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the air inlet assembly. 3. Remove the screws from the air inlet assembly. 4. Remove the recirculation actuator screws. 5. Remove the recirculation actuator. INSTALLATION PROCEDURE Page 3281 13. Install the camshaft cover. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 6028 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 7868 6. Remove the transfer case adapter mounting bolts from the transmission. 7. Remove the transfer case adapter from the transmission. 8. Remove the transfer case adapter seal. Installation Procedure Page 14830 Electrical Symbols Part 7 Page 13971 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1269 Locations View - HVAC Systems - Automatic Page 15351 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 15117 Electrical Symbols Part 8 Page 15113 Electrical Symbols Part 4 Page 14039 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12048 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12496 Page 9028 7. Remove the rear brake rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate bolts. 11. Remove the park brake actuator lever housing from the backing plate. 12. Using denatured alcohol, clean the backing plate and parking brake actuator. 13. Using non-lubricated, filtered air, dry the backing plate. Installation Procedure Page 15494 Electrical Symbols Part 6 Page 15728 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10945 9. Use the J 26549-E in order to remove the expansion tube. 10. Remove the expansion tube from the evaporator tube. Installation Procedure Important: Install the shorter screen end of the expansion tube into the evaporator tube (6) first. 1. Use the J 26549-E in order to install the expansion tube. 2. Install the new O-ring seal. 3. Assebmle the evaporator tubes (4,6). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator tube nut. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Connect the evaporator tube (4) to the evaporator (1). 6. Install the nut (3). Tighten Tighten the nut to 28 N.m (21 lb ft). 7. Install the coolant reservoir. Page 10696 1. Install the air outlet duct-rear (3) to the console support bracket (1). 2. Install the push pin (1). 3. install the console support bracket. Locations Locations View Page 10892 Control Module HVAC: Service and Repair Blower Motor Processor Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the HVAC module-auxiliary. 3. Disconnect the electrical connector from the blower motor processor (1). 4. Remove the retaining screws from the blower motor processor (1). 5. Remove the blower motor processor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the blower motor processor (1) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws to the blower motor processor (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the HVAC module-auxiliary. 4. Connect the electrical connector to the blower motor processor (1). 5. Install the right rear quarter trim panel. Page 3832 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8139 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 14794 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 14926 Electrical Symbols Part 8 Page 7162 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Page 1808 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 7755 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 14873 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 11600 6. Reach up behind the wheelhouse panel and pass the end of the radio antenna cable assembly through the cowl opening (1). 7. Install the antenna cable grommet assembly to the cowl opening. 8. Install the wheelhouse panel. 9. Install the radio antenna cable (2) to the radio extension cable. 10. Close the I/P compartment. One-Piece Propeller Shaft Page 13569 9. Install the auxiliary air conditioning duct to the vehicle with the bolt. Tighten Tighten the auxiliary air conditioning duct bolt to 10 N.m (88 lb in). 10. Connect the coax cable (1) to the navigation antenna, if equipped. 11. Connect the rain sensor electrical connector (2), if equipped. 12. Connect the inside rear view mirror electrical connector (3). 13. Install the windshield rearview mirror wire harness cover. 14. Install the video display. 15. If equipped, install the front and rear overhead console. Page 2362 Accessory Drive Belt Routing Page 3957 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1270 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch - HVAC Systems Manual A/C Low Pressure Switch - HVAC Systems Automatic Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6745 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 1. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 3. Install the motor/encoder electrical connector. 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 7489 Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. Page 1700 Electrical Symbols Part 7 Page 5140 Electrical Symbols Part 3 Page 13980 Front Passenger Door Module (FPDM) C1 Page 9383 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 12686 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15710 Electrical Symbols Part 5 Page 8218 Page 5456 Electrical Symbols Part 4 Page 15693 Equivalents - Decimal And Metric Part 1 Page 12694 Steering Mounted Controls Transmitter: Description and Operation STEERING WHEEL CONTROLS The steering wheel controls for the HVAC system include air temperature and blower motor speed adjustments. Pressing the up arrow on the air temperature switch increases the outlet air temperature. Pressing the down arrow on the air temperature switch decreases the outlet air temperature. The Body Control Module (BCM) receives the input from the steering wheel controls. Pressing one of the steering wheel switches enables an in line resistor to drop voltage on the remote radio control signal circuit. The BCM then interprets this voltage signal and sends a class 2 message to the HVAC control module for the desired change. Testing and Inspection Mirror Memory Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Doors; Testing and Inspection. Page 15590 Electrical Symbols Part 6 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 3475 Disclaimer Page 15271 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 4427 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 6778 11. Using J2845fl release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 5861 Electrical Symbols Part 8 Page 5894 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 13849 Disclaimer Page 4639 Various symbols are used in order to describe different service operations. Page 3706 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 8183 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 10291 7. Disconnect the outer tie rod from the steering knuckle using J24319-B. 8. Remove the brake hose bracket retaining bolts. 9. Remove the brake hose bracket from the steering knuckle. 10. Remove the upper control arm to the steering knuckle pinch bolt and nut. 11. Disconnect the upper control arm from the steering knuckle. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 5324 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 4292 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15886 Electrical Symbols Part 1 Page 8728 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer A/C - Slow to Cool in Hot/Humid Conditions Fan Clutch: All Technical Service Bulletins A/C - Slow to Cool in Hot/Humid Conditions Bulletin No.: 04-01-38-019A Date: June 07, 2005 TECHNICAL Subject: Intermittent Slow to Cool HVAC Performance Concerns in High Ambient Temperatures and/or High Humidity Conditions After Start Up, Especially at Low Engine Speeds (Install New Engine Cooling Fan Clutch) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005 Saab 9-7X Supercede: This bulletin is being revised to provide repair information for this customer concern. Please discard Corporate Bulletin Number 04-01-38-019 (Section 01 - HVAC). Condition Some customers may comment on slow to cool Air Conditioning (A/C) performance or high A/C outlet temperatures after start up or that the A/C system is not cooling sufficiently, especially in high ambient temperatures. This may be an intermittent condition and the performance of the Heating, Ventilation and Air Conditioning (HVAC) system may not meet customer expectations. Cause This condition may be caused by the response of the Electro-Viscous (EV) fan clutch and can be related to airflow across the condenser. This low A/C system performance can occur for longer periods of time if the vehicle is allowed to idle or is driven in low speed conditions. The response of the EV fan clutch will affect A/C system performance. As higher road speeds are attained, the increased airflow across the condenser will usually improve A/C system performance and the response of the EV fan clutch. This condition may be more evident after the vehicle has set for a period of time and can be difficult to duplicate. The condition may occur after the vehicle has set for as little as 10 minutes or as long as overnight. It is most prevalent intermittently during the first 15 minutes of operation. Correction Technicians are to replace the EV fan clutch with a new design part, P/N 15293048, on vehicles built before June 2005. Vehicles built in June 2005 may already have the updated EV fan clutch and it will not need to be replaced. For 2004 model year vehicles and older, update the Powertrain Control Module (PCM) with a software calibration that was developed to improve coolant temperature gauge readings. This new calibration will cause the PCM to command small amounts of additional fan engagement to better control engine coolant temperatures. Model year 2005 vehicles already have this calibration installed. Refer to Corporate Service Bulletin Number 04-06-02-005 for more information about this calibration. Proper diagnosis of any customer concern is essential. Refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure in SI to begin a diagnosis of any HVAC concerns. Refer to the Diagnostic Starting Point-Engine Cooling procedure in SI to begin a diagnosis of any engine cooling or engine cooling fan concerns. If an attempt is made to diagnose an HVAC system concern, all parameters must be measured. As an example, both the low and high side refrigerant pressure readings must be measured. If only the low side pressure readings were measured, it would appear that the A/C compressor is disengaging at a higher pressure than expected. If both the low and high side pressures were being measured, it would be noted that the A/C compressor is probably disengaging due to the maximum high side pressure cut out point being reached. This occurs to protect the HVAC system from damage. The updated PCM software calibration along with the updated EV fan clutch will improve this condition due to increased air flow across the condenser. The new EV fan clutch has an increased minimum operating fan speed and an improved response time. Additional engine cooling Page 14071 Liftgate Module (LGM) C3 (Except XUV) Page 6170 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Page 4016 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 6968 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Page 10425 Vehicle Lifting Points 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center Page 13939 Locations View Page 14181 Head Rest: Removal and Replacement Head Restraint Replacement - Front Seat Head Restraint Replacement - Front Seat Removal Procedure 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. Installation Procedure 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Head Restraint Guide Replacement - Front Seat Head Restraint Guide Replacement - Front Seat Removal Procedure 1. Remove the front seat assembly. 2. Remove the front seat head restraint. 3. Pull the seat back cover and the seat back pad up high enough to expose the head restraint guides. Refer to Seat Back Cover and Pad Replacement - Front. 4. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the guides from the seat frame. 5. Remove the guides from the seat back frame. Page 2715 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 13886 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 4548 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 6. Install the rear electrical center cover. 7. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 4817 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5878 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 12009 4. Carefully pull down on the rearward edge of the headliner in order to expose the rear bracket retaining bolt. 5. Remove the rear retaining bolt. 6. Carefully remove the bracket from the vehicle through the headliner opening. INSTALLATION PROCEDURE 1. Carefully install the bracket to the vehicle through the headliner opening, ensuring the locating tabs (1) are fully seated to the roof bow. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 6233 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13973 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8683 Page 8092 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 1481 Crankshaft Position (CKP) Sensor Page 14614 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 5619 Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. Page 8821 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the closeout/insulator panel. 2. Remove the stoplamp switch from the brake pedal. 3. Remove the brake pedal pivot bolt and discard the bolt. 4. Remove the brake pedal. 5. Inspect the brake pedal pivot bushing for damage or wear. Installation Procedure 1. If the brake pedal pivot bushing is damaged or worn, replace the bushing using the following procedure: 1.1. Squeeze the end that will be facing the brake pedal pivot nut. 1.2. Insert the bushing into the pivot hub just enough to hold the bushing in place. 1.3. Push the bushing through the hub until the bushing snaps in place. 2. Install the brake pedal. Notice: Refer to Fastener Notice in Service Precautions. Important: The brake pedal pivot bolt is a prevailing torque bolt and must be replaced each time the bolt is removed. 3. Install the new brake pedal pivot bolt and the brake pedal pivot nut. ^ Tighten the brake pedal pivot bolt to 25 Nm (19 ft. lbs.). 4. Install the stoplamp switch to the brake pedal. 5. Install the closeout/insulator panel. Page 15776 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6973 Fluid Pump: Specifications Pump Assembly to Case Bolt ................................................................................................................................................... 26.0-32.0 Nm (19-24 ft. lbs.) Pump Cover to Pump Body Bolt .............................................................................................................................................. 20.0-27.0 Nm (15-20 ft. lbs.) Page 11195 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 10653 1. Remove the console. 2. Remove the screw from the air outlet duct. 3. Remove the air outlet duct from the console. 4. Remove the rear mode actuator retaining screws. 5. Remove the rear mode actuator. INSTALLATION PROCEDURE Page 13967 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 299 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 11855 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 6561 For vehicles repaired under warranty, use the table. Disclaimer Page 11672 Electrical Symbols Part 7 Page 6910 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON- III transmission fluid. Refer to Transmission Fluid Checking Procedure. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 15501 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 2309 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The tender to radiator support rod will be removed as part of the radiator support cover. 1. Remove the radiator support cover. 2. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator. 3. Remove the air cleaner element (1) by grasping the filter and removing it from the air cleaner outlet duct (2) with a twisting and pulling motion. 4. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 14898 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Page 6578 Disclaimer Front Stabilizer Link: Service and Repair Front Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link to stabilizer shaft retaining nut. 3. Remove the stabilizer shaft link to lower control arm retaining nut. Notice: Do not pry on the stabilizer shaft link. Use care when removing or installing the stabilizer shaft link in order to avoid tearing or puncturing the stabilizer shaft link boot. Damage to the stabilizer shaft link boot will lead to damage to the stabilizer shaft link. 4. Remove the stabilizer shaft link and washer. Installation Procedure Important: There is a washer between the stabilizer shaft link and the lower control arm made of hardened steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. Page 768 Powertrain Control Module (PCM) C2 Part 1 Page 7983 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4564 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 1320 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 6152 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: All Technical Service Bulletins Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure. Page 14126 5. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. 6. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. Important: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. Page 9058 2. Position the shoe (2) on the actuation mechanism. 3. Holding the lower end of the shoe (2) away from the backing plate, slide the shoe down, over the top of the hold down spring (3). 4. Place the lower end of the shoe (2) against the backing plate. 5. Slide the shoe (2) up and under the hold down spring (3). 6. Inspect the position of the shoe assembly. The shoe must be central on the backing plate and with both tips located in the slots of the actuation mechanism (1). 7. Manually check the park brake for proper operation by moving the park brake actuator lever and observing the movement of the actuation mechanism. 8. Install the park brake cable to the park brake lever. 9. Adjust the park brake shoe (1). 10. Install the brake rotor. Page 14176 2. Verify that the retaining clips are fully seated. 3. Install the rear seat head restraint posts to the head restraint retractor, verifying that the notches in the head restraint posts are indexed toward the back of the seat. 4. Lower the head restraint to the full down position. Head Restraint Guide Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the head restraint. 2. Remove the seat back cover and pad high enough to expose the head restraint guides. 3. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. INSTALLATION PROCEDURE Page 15274 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 15244 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 14291 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 1410 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 5552 6. Install the fuel return pipe retainer. Tighten Tighten the return pipe retainer screw to 8 N.m (71 lb in). 7. Connect the fuel return pipe. 8. Connect the fuel pressure regulator vacuum line. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition. 10.4. Inspect for fuel leaks. 11. Install the engine wiring harness into the retaining clips at the front of the engine. 12. Install the air intake resonator. Page 3570 1. Apply coolant to the end of the heater inlet hose. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 4593 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Locations Locations View Page 10167 For vehicles repaired under warranty, use the table. Disclaimer Page 1540 Equivalents - Decimal And Metric Part 1 Page 1866 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 13962 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 4248 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 5236 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 7055 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 11209 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Page 5030 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 14509 Position Sensor - Horizontal Motor (W/Memory Seat) Position Sensor - Recline Motor (W/Memory Seat) Specifications Pressure Regulating Solenoid: Specifications Pressure Control Solenoid Bracket to Valve Body Bolt .............................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 13766 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 7911 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10015 1. Install the power steering cooler to the radiator support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering cooler mounting bolts. Tighten the power steering cooler mounting bolts to 20 Nm (15 ft. lbs.). 3. Connect the power steering hoses assembly to the power steering cooler. 4. Remove drain pan from under the vehicle. 5. Install the radiator air intake baffle. Page 5550 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Assembly The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. The fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. Diagrams Turn Signal Switch: Diagrams Turn Signal/Multifunction Switch C1 Part 1 Turn Signal/Multifunction Switch C1 Part 2 Page 14427 4. Release the J strips (1,3) on each side of the seat cushion. 5. Release the front/rear J strips (2,4). 6. Remove the SIR electrical harness (2) from the seat pan. 7. Remove the seat electrical harness from the seat pan. 8. Remove the wire harness fasteners from the seat pan. 9. Disconnect the seat cushion heater electrical connector, if equipped. Important: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the seat pad. 10. Separate the hook and loop retaining strips. 11. Remove the hog rings (1) from the bottom rear side of the cover. 12. Remove the 11 hog rings from the top side of the cover. 13. Remove the seat cushion trim cover and pad from the seat frame. 14. Remove the seat module retaining screw, if equipped. 15. Remove the seat module, if equipped. 16. Remove the seat cover from the seat cushion. 17. Remove the seat cushion from the seat pan. Installation Procedure 1. Install the seat cushion to the seat pan. 2. Install the seat cover to the seat cushion. 3. Using a side to side motion, carefully pull the seat cushion cover onto the seat pan. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 3968 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5709 1. Install the resonator assembly to the engine making sure that the crankcase ventilation hose (1) is connected to the port (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the resonator to engine bolts (4). Tighten Tighten the resonator to engine bolts to 6 N.m (53 lb in). 3. Install the air cleaner outlet duct to the resonator. 4. Make sure the resonator is properly fit to the throttle body assembly. Tighten Tighten the throttle body clamp (1) to 4 N.m (35 lb in). 5. Connect the fuel pressure regulator vacuum supply to the resonator. Page 4646 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet Trailblazer, Envoy, and Bravada TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater Inlet hoses. Front Wheel Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Bearing Replacement Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the brake rotor. 6. Disengage the wheel drive shaft from the wheel hub and bearing. Place a brass drift against the outer end of the wheel drive shaft in order to protect the wheel drive shaft threads. Sharply strike the brass drift with the hammer. Do not attempt to remove the wheel drive shaft from the wheel hub and bearing at this time. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 6036 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 13723 Driver Door Module (DDM) C3 Page 10693 4. Remove the air outlet from the housing assembly. INSTALLATION PROCEDURE 1. Position the air outlet face down at the housing opening. 2. Position the right side of the air outlet below the housing retaining pin. 3. Seat the right side of the air outlet to the housing retaining pin by lifting upward. Recall 01V334000: Transfer Case Control Module Update PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 1020 Engine Controls - Hesitation/Idle Fluctuation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Idle Fluctuation Bulletin No.: 03-06-04-018A Date: December 08, 2003 TECHNICAL Subject: Cold Idle Fluctuation at Altitude, Hesitation on Acceleration or 1-2 Upshift Delay (Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VINs - RPO LL8) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 03-06-04-018 (Section 06-Engine). Condition Some customers may comment on one of the following conditions: - Idle fluctuation for a few seconds on the first start up after an overnight soak at higher altitudes. - Hesitation on acceleration, this typically occurs with engine coolant temperatures between 60-80°C (140-175°F). - 1-2 upshift delay at throttle openings of 25% or less and ECT between 7-30°C (45-85°F). Cause The existing PCM calibration may not be optimized for all conditions. Correction Reprogram the PCM with the latest service calibration available from Techline. The Calibrations are electronic calibrations and are NOT available from GMSPO. Calibrations were available from Techline starting February 22, 2003, on the TIS 2000 version 2.5 for 2003 data update or later. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test ^ Tools Required J 35667-A Cylinder Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the diagnosis. The cylinder leakage test may be used in conjunction with the engine compression test, to isolate the cause of leaking cylinders. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the battery ground (negative) cable. 2. Remove the spark plugs. 3. Install J 35667-A. 4. Measure each cylinder on the compression stroke, with the valves closed. Important: It may be necessary to hold the crankshaft balancer bolt, to prevent piston movement. 5. Apply air pressure, using J 35667-A. Refer to the manufacturer's instructions. 6. Record the cylinder leakage readings for each cylinder. Important: ^ Normal cylinder leakage is from 12 to 18 percent. ^ Make a note of any cylinder with more leakage than the other cylinders. ^ Any cylinder with 30 percent leakage or more requires service. 7. Inspect the four primary areas, to properly diagnose a leaking cylinder. 8. If air is heard from the intake or exhaust system, perform the following procedure: ^ Remove the camshaft cover. Ensure the valves are closed. - Inspect the cylinder head for a broken valve spring. ^ Remove the cylinder head and inspect. 9. If air is heard from the crankcase system at the crankcase (oil filler tube), perform the following procedure: ^ Remove the piston from the suspect cylinder. ^ Inspect the piston and connecting rod assembly. ^ Inspect the engine block. 10. If bubbles are found in the radiator, perform the following procedure: ^ Remove the cylinder head and inspect. ^ Inspect the engine block. 11. Remove the J 35667-A. 12. Install the spark plugs. 13. Install the battery ground (negative) cable. Engine Controls - MIL ON/Delayed Downshift/Fan Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Delayed Downshift/Fan Noise File In Section: 06 - Engine/propulsion System Bulletin No.: 01-06-04-052B Date: May, 2004 OBD SOFTWARE UPGRADE Subject: On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the powertrain control module (PCM) on all affected vehicles, as identified above, including vehicles in new dealer inventory, used inventory, and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table. *This a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide. Page 9195 5. Disconnect the positive cable lead from the junction block (1). 6. Disconnect the positive cable lead from the generator (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 4702 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9789 C201 Part 3 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 10125 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9741 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 14394 5. Remove the rear seat belt anchor nut (2). 6. Unhook the J-strips (2) from the bottom of the seat back cover (1). 7. Remove the two push pins (1) from each side of the seat back. 8. Pull the seat cover forward through the opening between the seat cushion and the seat back. Page 4932 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 6. Install the rear electrical center cover. 7. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 4358 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Page 382 Electrical Symbols Part 6 Page 14271 Position Sensor - Horizontal Motor (W/Memory Seat) Position Sensor - Recline Motor (W/Memory Seat) Page 1001 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 4280 Electrical Symbols Part 8 Specifications Drain Plug: Specifications Front Drive Axle Plug, Drain and Fill .............................................................................................................................. ................................................ 32 Nm (24 ft. lbs.) Rear Drive Axle Drain Plug ............................................................................................................................................ ................................................. 48 Nm (35 ft. lbs.) Page 9243 5. Remove the right engine lift hook bolts and remove the lift hook. 6. Remove the 3 generator mounting bolts and remove the generator. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 15512 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 13639 11. Return the third row seats to the upright position. 12. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Left (TrailBlazer EXT, Envoy XL) Trim Panel Replacement - Rear Quarter - Left (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the left body side window rear garnish molding.. 4. Remove the left body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the left rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Remove the auxiliary power outlet from the trim panel. 9. Release the five screws that retain the rear quarter trim panel to the body. 10. Remove the rear quarter trim panel from the vehicle. Installation Procedure Page 553 Control Module HVAC: Service and Repair Blower Motor Processor Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the HVAC module-auxiliary. 3. Disconnect the electrical connector from the blower motor processor (1). 4. Remove the retaining screws from the blower motor processor (1). 5. Remove the blower motor processor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the blower motor processor (1) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws to the blower motor processor (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the HVAC module-auxiliary. 4. Connect the electrical connector to the blower motor processor (1). 5. Install the right rear quarter trim panel. Page 14437 1. Release the J-strips that retain the cover to the seat pan. 2. Compress the foam and partially remove the seat cover assembly from the seat pan. Important: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 3. Remove the cover from the cushion by separating the retaining strips. 4. Separate and remove the cushion and cover assembly from the seat pan. 5. Release the reinforcement bar from the hog-rings. 6. Remove the cover from the cushion. Installation Procedure 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. Seat Cushion Cover and Pad Replacement - Rear No. 2 Seat Cushion Cover and Pad Replacement - Rear No. 2 Removal Procedure 1. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the rear seat cushion assembly. Page 229 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 14728 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Page 5716 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 4565 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 12400 For vehicles repaired under warranty, use the table. Disclaimer Page 10637 Air Temperature Actuator - Left Console Mode Actuator (Body Type VIN 6) Page 2414 Oil Filter: Technical Service Bulletins Engine - Oil Filter Usage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-026 Date: November, 2001 INFORMATION Subject: Oil Filter Usage Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) The correct oil filter to be used for replacement is the AC Delco PF-58. The correct part number for the filter is P/N 25014377 (in Canada, use P/N 729865). New vehicles may have a different filter installed from the factory. Use only the AC Delco PF-58 when changing the filter. Parts are currently available from GMSPO. DISCLAIMER Page 634 Horn Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the horn relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the horn relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 4965 Electrical Symbols Part 4 Page 480 Liftgate Module (LGM) C3 (Except XUV) Page 410 Conversion - English/Metric Page 14441 6. Remove the seat cover J-strips (1) from the seat cushion trim panel (2). 7. Remove the screws securing the seat cushion trim panel to the seat frame. 8. Remove the seat cushion trim panel. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the screws securing the seat cushion trim panel to the seat cushion assembly. Tighten the rear seat cushion trim panel screws to 2 N.m (18 lb in). 2. Install the seat cover J-strips (1) to the seat cushion trim panel (2). 3. Install the two bolts (2) securing the support (1) to the seat cushion trim panel. Page 12104 1. Install the processor bracket to the rear seat studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the rear seat back stud. Tighten Tighten the nut to 45 N.m (33 lb ft). 3. Position the upper bracket to the processor bracket. 4. Slide the upper bracket outboard until all the retaining tabs are seated to the processor bracket. 5. Install the communication interface module. 6. Install the right rear seat cushion. Page 5014 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Liftglass Ajar Switch Exhaust - Exhaust Noise/Leak Exhaust Manifold Gasket: All Technical Service Bulletins Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 2777 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Description and Operation Security Lamp/Indicator: Description and Operation SECURITY INDICATOR - 1 The SECURITY indicator on the instrument cluster is controlled by both the VTD system and the CTD system. The SECURITY indicator is an LED on the instrument cluster which illuminates the word SECURITY. The SECURITY indicator is controlled by the body control module grounding the security indicator control circuit. The VTD system commands the instrument cluster to control the indicator only when the ignition switch is ON. The VTD system uses the indicator as a malfunction indicator. - The CTD system commands the instrument cluster to control the indicator only when the ignition switch is OFF. The CTD system uses the indicator to identify system status. SECURITY INDICATOR - 2 The Instrument Panel Cluster (IPC) illuminates the SECURITY indicator as determined by the Vehicle Theft Deterrent (VTD) system. The IPC receives a message via the serial data circuit from the theft deterrent control module requesting illumination. The VTD system requests the IPC to illuminate the indicator only when the ignition is ON. The VTD system uses the indicator as a malfunction indicator. For vehicle theft deterrent (VTD) information, refer to Vehicle Theft Deterrent (VTD) Description and Operation. SECURITY INDICATOR OPERATION The theft deterrent control module can command the instrument cluster to illuminate the SECURITY indicator only when the ignition key is in the ON position. If the PCM loses communication with the theft deterrent control module, the instrument cluster will also detect the loss of communication and will illuminate the SECURITY indicator. The SECURITY indicator can indicate both malfunctions, Indicator on steady and tamper, Indicator flashing. A flashing indicator indicates unauthorized operation. Under the following conditions the SECURITY indicator may be commanded to illuminate. SECURITY Indicator Illuminates when Engine is Running If the theft deterrent control module is unable to measure the ignition key transponder value or the PCM loses communication with the theft deterrent control module while the engine is running, the indicator will be illuminated. SECURITY Indicator Illuminated and Engine Does Not Start If the theft deterrent control module was unable to measure the ignition key transponder value or the PCM has detected a problem with the theft deterrent system. The VTD system is in Learn Mode. Refer to Programming Theft Deterrent System Components. SECURITY Indicator Flashes and Engine Does Not Start The theft deterrent control module has measured an incorrect transponder value, the calculation to the challenge is incorrect or the PCM has lost communication with the theft deterrent control module, The VTD system considers this a tamper condition. The VTD indicator will flash. Page 1455 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 11688 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 14089 5. Install and secure the finish covers (3) to the side rails. Luggage Carrier Slats Replacement TOOLS REQUIRED J 25070 Heat Gun REMOVAL PROCEDURE 1. Mark the location of the luggage carrier slats on the roof with masking tape. 2. Use tape to protect the mounting surface during removal. 3. To remove the luggage carrier slats, heat the slats using J 25070. Apply heat in a circular motion for 30 seconds. NOTE: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 4. Use a plastic, flat-bladed tool to lift or remove the slats from the vehicle. 5. Remove the luggage carrier slats from the vehicle. 6. When replacing the slats, remove all of the adhesive using a 3M(TM) Scotch Brite molding adhesive remover disk, 3M(TM) P/N 07501 or equivalent. INSTALLATION PROCEDURE IMPORTANT: Apply the slats in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Heat the mounting surface to approximately 27-41°C (80-105°F). 2. Ensure that the temperature of the slats is approximately 29-32°C (85-90°F). Page 11955 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 5239 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8436 Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 7337 17. Install the front stabilizer bar links to the frame. Refer to Stabilizer Shaft Link Replacement in Front Suspension. 18. Install the brake hose retaining bolts. Tighten Tighten the brake hose retaining bolt to 25 N.m (18 lb ft). Disclaimer Page 14764 Various symbols are used in order to describe different service operations. Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 6820 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 4757 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications IMPORTANT: The following steps must be completed before using the symptom tables: 1. Perform the Diagnostic System Check for the subsystem exhibiting the symptoms. The subsystem diagnostic system check will identify where to begin diagnosis of the data link communication system. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices that could affect the operation of the serial data communications systems. Refer to Checking Aftermarket Accessories in Diagnostic Aids. - Inspect the easily accessible systems or visible system components for obvious damage or conditions that could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate With Class 2 Device CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. - When the class 2 serial data circuit: is shorted to ground - is shorted to voltage The following DTCs may set: U1300 - U1301 - U1305 TEST DESCRIPTION Page 5688 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Weatherstrip Replacement - Lift Gate Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. Installation Procedure 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Page 12073 Conversion - English/Metric Page 13322 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Page 9707 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 6665 Page 13419 Tighten the bolts to 50 N.m (37 lb ft). 2. Lower the vehicle. Page 571 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 953 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 12129 4. Inspect the harness at the pinched location (2) and repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 5. Verify proper installation of the harness clip (1) that attaches the harness to the body. Reinstall if necessary. 6. Install the carpet back into place. 7. Install the right rear door sill plate. 8. Install the right rear seat back. Refer to the Seats sub-section of the Service Manual for the Seat Back Replacement procedure (SI2000 Document ID # 741140). Parts Information Parts are expected to be available from GMSPO October 15, 2001. Warranty Information For vehicles repaired under warranty, use the table. Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 8066 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 14741 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9927 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Diagrams Engine Oil Level And Temperature Sensor Page 15794 Daytime Running Lamp: Description and Operation The ambient light sensor is a light sensitive transistor that varies its voltage signal to the Body Control Module (BCM) in response to changes to the outside (ambient) light level. When the BCM receives this signal it will either turn on the Daytime Running Lamps (DRL) through the HDM using the reduced output or the headlamps at full intensity for auto headlamp operation. Any function or condition that turns on the headlights will cancel the daytime running lamps operation. The daytime running lamps (DRL) are the low beam headlights at a reduced intensity. With the headlight switch in the OFF position, the headlights will either be turned ON or OFF, after an approximate 8 second delay depending on whether daylight or low light conditions are sensed. When the BCM signals the HDM for DRL operation in daylight conditions, the HDM illuminates the low beam headlights at a reduced intensity. The DRL will operate when the ignition switch is in the RUN position, the gear selector is not in the PARK position and the parking brake is released. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. DRL operation in Manual Transmission equipped vehicles will occur when the ignition switch is in the RUN position, and the parking brake is released. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 13930 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4987 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5876 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10399 7. Install pieces of heater hose to the shock module spring where J45400 contacts lower part of spring. 8. Install the shock module (2) into the J45400 (1). Important: The spring is compressed when the shock absorber moves freely. 9. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed. 10. Remove the shock absorber upper retaining nut. 11. Remove the shock absorber from the shock module. 12. Loosen the compressor forcing screw until the upper mounting plate and coil spring may be removed. 13. Remove the upper mounting plate and coil spring from the J45400. Installation Procedure 1. Install the coil spring and upper mounting plate to the J45400. Page 4721 Various symbols are used in order to describe different service operations. Page 10636 Air Door Actuator / Motor: Diagrams HVAC Systems - Automatic Air Temperature Actuator - Auxiliary (Body Type VIN 6) Air Temperature Actuator - Right Page 9933 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Page 1430 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 3227 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14806 Page 12091 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Page 12985 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip (1) retaining the lock rod (2) to the outside door handle. 4. Remove the lock rod (2) from the outside door handle. 5. Remove the nuts retaining the outside door handle to the door. 6. Remove the outside door handle from the door. INSTALLATION PROCEDURE 1. Install the outside door handle to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the outside door handle to the door. Tighten Tighten the nuts to 10 N.m (89 lb in). 3. Install the lock rod (2) to the outside door handle. 4. Install the clip (1) retaining the lock rod (2) to the outside door handle. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 13638 8. Release the five screws that retain the rear quarter trim panel to the body. 9. Remove the rear quarter trim panel from the vehicle. INSTALLATION PROCEDURE 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Connect the wiring harness connector to the auxiliary power outlet. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the five screws that the retain the rear quarter trim panel to the body. Tighten Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 6. Install the seat belt lower anchor. Tighten Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 7. Install the right rear door sill panel. 8. Install the liftgate sill plate. 9. Install the right body side window forward garnish molding. 10. Install the right body side window rear garnish molding. Page 2420 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Page 14672 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Rear Door Opening REMOVAL PROCEDURE Page 12342 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 12250 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 5100 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4984 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 1397 Electrical Symbols Part 4 Page 2076 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11346 Disclaimer Page 13709 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6003 Various symbols are used in order to describe different service operations. Page 5819 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8121 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 12537 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15304 Electrical Symbols Part 6 Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Removal Procedure 1. Use a flat bladed tool in order to open the front and rear bezel covers. 2. Position the stem of a flat bladed tool at the rear bezel. 3. Push the rear bezel rearward 6 mm (1/4 in) and pull down on the handle in order to release the roof panel retaining tab. 4. Position the stem of a flat bladed tool at the inside edge of the front bezel assembly. 5. Push the front bezel assembly forward 6 mm (1/4 in) and pull down on the handle in order to release the roof panel retaining tab. 6. Partially lower the headliner in order to expose the rear handle retaining tab (1). 7. Insert the tip of a flat bladed tool into the rear retaining tab (1). 8. With the retaining tab (1) released, pull down on the handle in order to release the roof panel tab from the bezel. Page 8205 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the screws from the heater core cover-auxiliary (3). 3. Remove the heater core cover-auxiliary (3). INSTALLATION PROCEDURE 1. Install the heater core cover-auxiliary (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the heater core cover-auxiliary. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the right rear quarter trim panel. Page 14124 Important: Midway through the rotation cycle, the tool will move further into the access hole. 6. Push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade pivot arm bezel should appear to be recessed into the bezel. Important: Ensure the pivot arm is recessed into the bezel before removing the sunshade from the headliner. 7. Apply outboard pressure to the sunshade while the sunshade is parallel to the windshield. 8. Pull the sunshade downward while maintaining outboard pressure to the sunshade. You will notice a separation between the headliner and the sunshade bezel. 9. In order to remove the sunshade from the headliner, carefully grab the headliner at the windshield pillar area and apply downward pressure while gently rocking the sunshade up and down. Luggage Carrier - Windnoise Roof Rack Frame: Customer Interest Luggage Carrier - Windnoise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-58-004 Date: September, 2001 TECHNICAL Subject: Windnoise or Gap Between Luggage Carrier Side Rail Front Cover and Roof Sheet Metal (Secure Front Side Rail Corners and/or Reposition Cross Bows) Models: 2002 Chevrolet and GMC SIT Utility Models (Trail Blazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment about wind noise coming from the roof or luggage carrier area when driving at highway speeds. Also comments may be received about a gap between the luggage carrier side rail front cover(s) and the roof sheet metal. Cause One or both of the following may cause the conditions: Cause # 1 The bolt attaching the luggage carrier side rail front corner (1) may be over tightened, causing the mounting surface to lift up leaving a gap (3) between it and the roof sheet metal (2). This can occur on either the left or right side rail front corner. Cause # 2 The luggage carrier front (2) and rear cross bows (1) are not positioned correctly when not in use. Correction Correction # 1 Page 9821 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 12672 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 15235 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver Page 342 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Locations Fuel Pump Relay: Locations FUEL PUMP RELAY Locations View Page 45 Page 2929 Important: Before using trim tool assembly EN 45680-411 the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface. Important: Ensure that the set gage ring EN 45680-412 surfaces are clean. 6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the trim tool assembly EN 45680-411 height until the blades are worn or damaged. 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 Nm (14 lb ft). Page 6462 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Page 15506 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6951 17. A hidden yellow identification band indicates proper joint seating. 18. Install the cooling line ends (4) to the transmission. 19. Raise the transmission into position. 20. Install the front exhaust pipe assembly. 21. Install the transmission support. 22. Remove the transmission jack. 23. Install the clip (2) that holds the cooler lines together. 24. Install the cooler lines to the retainer (1) located on the right side of the engine. 25. Install the front sections of the cooler lines to the vehicle. 26. Install the cooler lines to the retainer (1 ) located on the radiator shroud. 27. Connect the front and rear cooler lines at the quick connect fitting (2). 28. Install the cooler lines (3,4) to the radiator. 29. Remove the drain pan from under the vehicle. 30. Lower the vehicle. 31. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 9603 For vehicles repaired under warranty, use the table. Disclaimer Page 3827 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Locations Locations View Page 7073 Page 2376 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install 3/3 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drivebelt. 2. Remove the drivebelt. 3. Release the tension on the tensioner arm. Installation Procedure 1. Route the drivebelt over all the pulleys except the drivebelt tensioner pulley. 2. Install the 3/8 inch breaker bar on the drivebelt tensioner arm and turn the breaker bar clockwise. 3. Install the drivebelt over the drivebelt tensioner pulley. 4. Slowly release the tension to the drivebelt tensioner arm. 5. Inspect for proper installation of the drivebelt on the pulleys. Page 12037 Locations View Page 9835 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 2344 Spark Plug: Service and Repair Spark Plug Replacement Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 1740 Electrical Symbols Part 6 Page 1873 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 2832 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J43631. Installation Procedure 1. Install the stud into the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rotor. 6. Install the tire and wheel. 7. Lower the vehicle. Page 10091 5. Firmly pull rack and pinion boot (1) from the gear. Discard the rack and pinion boot (1) Installation Procedure Important: The arrows (2) on the boot must be aligned with the range (1) on the gear housing. 1. Apply grease provided to inside of rack and pinion boot ribs (4). 2. Place the new large seal retaining clamp (3) onto rack and pinion boot (4). 3. Install boot (4) over inner tie rod end. Align the arrows (2) on boot (4) with the range (1) marked on the gear housing. 4. Install the new small seal retaining clamp (2) over the boot (1). 5. Slide the boot (1) towards the center of the gear assembly until the boot seats in the inner tie rod retaining groove. Important: The boot (1) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (1) is not shaped properly, adjust by hand before installing the boot clamps (3,4). Be sure arrows on the boot (1) align with range on the gear housing. Page 5031 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9235 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 12791 Parts Information Parts are expected to be available 8-8-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2250 Windshield Washer Switch: Diagrams Rear Window Wiper/Washer Switch Windshield Wiper Washer Switch (Multifunction Switch C3) Page 4133 Electrical Symbols Part 4 Page 13189 Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Liftgate Window Weatherstrip Replacement - Lift Gate Window Removal Procedure 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. Installation Procedure 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Suspension - Boom/Rumble Heard at Highway Speeds Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Boom/Rumble Heard at Highway Speeds Bulletin No.: 02-03-09-002C Date: December 06, 2004 TECHNICAL Subject: Intermittent Boom, Rumbling Noise and/or Disturbance Heard in Passenger Compartment While Driving at Highway Speeds (Replace Rear Coil Springs) Models: 2002-2005 Chevrolet TrailBlazer 2002-2005 GMC Envoy with Rear Coil Springs 2003-2004 Oldsmobile Bravada with Rear Coil Springs Built Prior to August 23, 2004 (Refer to Parts Information table below for applicable RPO Code usage) Attention: Do not perform this bulletin for vehicles built after 8/23/04. Supercede: This bulletin is being revised to add the breakpoint of 8/23/2004 for 2005 model year production with an updated spring material. Please discard Corporate Bulletin Number 02-03-09-002B (Section 03 - Suspension). Condition Some customers may comment on an intermittent booming, rumbling noise and/or disturbance heard in the passenger compartment while driving the vehicle at highway speeds. This condition occurs while driving at steady speeds between 1550-1700 engine RPM in 4th gear (NOT during acceleration). This equates to 64-80 km/h (48-50 mph) for vehicles with a 4.10 axle ratio (RPO GT5), 83-86 km/h (52-54 mph) with a 3.73 axle ratio (RPO GT4) and 93-96 km/h (58-60 mph) with a 3.42 axle ratio (RPO GU6). Cause The noise/disturbance occurs when the torque converter momentarily goes to a full lock-up state, resulting in zero slip of the torque converter. When the torque converter returns to normal ECCC mode with 30 RPM of slip, the noise will go away. The disturbance generated by the zero slip condition is amplified and transferred into the passenger compartment by the rear coil springs. Correction Replace the rear coil springs using the following service procedure. Note: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. 2. Support the front frame rail of the vehicle with a suitable adjustable jack stand. 3. Support the rear axle with a suitable adjustable jackstand. 4. Remove the two shock absorber lower mounting bolts. 5. Lower the rear axle enough to remove the tension on the rear coil springs. 6. Remove the rear coil springs. Important: ^ It is critical that the correct coil springs are installed in the correct location. Page 13765 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. Page 5310 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 8734 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Inflatable Restraint Side Impact Sensor Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Page 5305 Electrical Symbols Part 4 Page 5291 Page 14093 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Page 5219 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9672 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 388 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 4712 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 14376 6. Install the seat back cover flap to the pad with the hog rings (2). 7. Install the J-strips (1) across the bottom of the seat back cover. 8. Install the J-strip (1) to the seat adjuster cross bar (2). 9. Install the screws (3) securing the extension panel (1) to the seat back. 10. Install the extension panel hinge trim (2). 11. Install the head restraint assembly. Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 11918 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 5647 6. Install the fuel fill pipe bracket nut (2). Tighten Tighten the fuel fill pipe bracket nut to 10 N.m (89 lb in). 7. Install the fuel fill pipe housing. 8. Install the fuel filler cap. Page 2263 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 12429 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 13571 27. Install the coat hooks to the roof panel. 28. Connect the cellular antenna coax cable to the inner coupling on the left body side window. 29. Connect the antenna module electrical connector to the right and left body side window. 30. Install the headliner harness to the left third pillar. 31. Install the headliner harness to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. 32. Install the ground terminals and the ground bolt to the left center pillar. Tighten Tighten the ground bolt to 10 N.m (88 lb in). 33. Reach underneath the carpet and install the 6 - way headliner harness electrical connector (1) to the cross-body wire harness. Page 12856 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 4079 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10857 HVAC Control Module- Auxiliary (Body Type VIN 6) Part 2 A/C - Inoperative Rear A/C Controls, DTC B0150 Control Assembly: Customer Interest A/C - Inoperative Rear A/C Controls, DTC B0150 File In Section: 01 - HVAC Bulletin No.: 02-01-39-003A Date: July, 2002 TECHNICAL Subject: Inoperative Rear HVAC Controls and/or DTC B0150 (Replace Rear HVAC Control) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Automatic HVAC Auxiliary Temperature Control (RPO CJ2) Built in May 2002 or Prior This bulletin is being revised to add service procedures and parts and warranty information. Please discard Corporate Bulletin Number 02-01-39-003 (Section 01 - HVAC). Condition Some customers may comment on an inoperative rear climate control panel. The controls may appear to not respond or to have very slow response for approximately one minute from starting the vehicle with limited temperature or mode range of the control. Diagnostic Trouble Code (DTC) B0150 may be stored in History. Some customers may associate this condition with a recent servicing that required the battery to be disconnected. Cause When the battery is disconnected from the vehicle for any reason, at the first key on the rear HVAC controller will reset and perform a test sequence, sweeping the temperature and mode doors to the full range of their travel. If during this test one of the rear HVAC module doors runs beyond the expected range, DTC B0150 will set. This code will disable the rear HVAC control. Due to production variances, the mode and temp doors may be traveling beyond their programmed range. Correction A revised rear HVAC controller has been released that eliminates DTC B0150 and has updated programming to allow for a greater expected range of motion. Vehicles built in April 2002 or prior that exhibit the above condition may be repaired using the following procedure. Vehicles built during May 2002 may have been assembled with the revised auxiliary temperature control panel. On step 1 of the following procedure, confirm the part number on the sticker attached to the rear auxiliary climate control panel. If the revised part number from the chart below is already installed, this bulletin does not apply to that vehicle. Use the following procedure to replace the rear HVAC controller: 1. Remove the rear HVAC controller by reaching in from the cupholder on the back of the floor console and pushing the controller out. 2. Disconnect 1 electrical connector from the rear of the HVAC controller. 3. Connect 1 electrical connector to the revised HVAC controller. 4. Install the rear HVAC controller by pushing inward until fully seated. 5. Start the engine and allow approximately one minute for the system to run its initial tests. Confirm the proper operation of the rear controller. Parts Information Parts are currently available from (3MSPO. Warranty Information Page 63 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 3213 Electrical Symbols Part 2 Page 1865 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Locations Locations View Page 8899 Notice: Refer to Fastener Notice in Service Precautions. 7. Install the lower brake caliper mounting bolt. ^ Tighten the brake caliper mounting bolt to 51 Nm (38 ft. lbs.). 8. Install the tire and wheel assembly. 9. Lower the vehicle. Refer to Vehicle Lifting. 10. Fill the brake master cylinder reservoir. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 11. Pump the brake pedal slowly and firmly to seat the brake pads. 12. Burnish the new brake pads. Rear Brake Pads Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. Page 4895 2. Install the heated oxygen sensor (2). Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 12929 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the outside rear view mirror (ORVM) wire harness from the door. 4. Carefully remove the water deflector from the door by releasing the adhesive backing. Installation Procedure 1. Position the water deflector to the door. 2. Press the water deflector to the door. Ensure that the water deflector forms a proper seal around the surface of the door panel. 3. Install the ORVM wire harness to the door. 4. Install the speaker. 5. Install the door trim panel. Page 5860 Electrical Symbols Part 7 Page 3876 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Driver Door Module (DDM) Locations View Page 10361 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 3031 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install 3/3 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drivebelt. 2. Remove the drivebelt. 3. Release the tension on the tensioner arm. Installation Procedure 1. Route the drivebelt over all the pulleys except the drivebelt tensioner pulley. 2. Install the 3/8 inch breaker bar on the drivebelt tensioner arm and turn the breaker bar clockwise. 3. Install the drivebelt over the drivebelt tensioner pulley. 4. Slowly release the tension to the drivebelt tensioner arm. 5. Inspect for proper installation of the drivebelt on the pulleys. Page 6658 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). Page 11154 Air Temperature Sensor Assembly - Inside Page 1899 Impact Sensor: Description and Operation Inflatable Restraint Sensing and Diagnostic Module INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 15413 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 12335 Page 9305 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 9368 Fuse Block - Rear C4 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 770 Powertrain Control Module (PCM) C3 Page 11282 45. Twist together 2 connector wire leads-the low circuits from both stages of the IP module-to the deployment harness wire. Refer to SIR Connector End Views in order to determine the correct circuits. 46. Inspect that the 3 wire connection is secure. 47. Bend flat the twisted connection. 48. Secure and insulate the 3 wire connection to the deployment harness using electrical tape. Page 14944 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 15015 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 5974 Electrical Symbols Part 4 Page 9370 Fuse Block - Underhood C2 Part 1 Page 13948 Electrical Symbols Part 7 Page 13078 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 2604 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 14273 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Page 278 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 9238 Various symbols are used in order to describe different service operations. Page 15405 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1082 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. Page 15145 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 9654 Fuse Block - Underhood C6 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 6301 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 15658 2. Mask off the desired amount of material to be removed. 3. Open the liftgate glass. Note: Do no damage the applique or the liftgate glass when removing the applique from the liftgate glass. 4. Remove the screws that retain the applique to the liftgate glass. 5. With a flat-bladed tool, carefully remove the applique from the liftgate glass. 6. Remove the CHMSL harness grommet from the roof panel. 7. Disconnect the CHMSL harness connector and remove CHMSL applique from the vehicle. 8. Using a 1/4" die grinder and Scotch-Brite(R) Disc, 3M(R) P/N 07481, remove excess material from the applique. 9. Paint the applique to match. Important: If the original part is used, it is important to seal (clear coat) the edge to protect the clear coat from lifting. 10. Remove the old adhesive from the underside of the applique. 11. Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 12. Apply double-sided adhesive tape, 3M(R) P/N 06397, or equivalent, to the underside of the CHMSL applique. 13. Remove the old adhesive from the liftgate glass. Important: ^ The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. ^ DO NOT use commercial glass or surface cleaners. These may contain petroleum. ^ The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). 14. Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 15. Apply adhesive promoter, P/N 12378555, in Canada, use P/N 88901239, to the liftgate glass surface, completely wetting the applique application Page 1787 Electrical Symbols Part 7 Page 12818 Disclaimer Technical Service Bulletin # 02-08-62-004B Date: 060602 Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. Page 9303 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 11268 7. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. IMPORTANT: Dual stage deployments are only used in the steering wheel and IP inflator modules, if the vehicle is equipped. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. If disposal of a deployed or undeployed dual stage module is required, both deployment loops must be energized to deploy the inflator module. 8. Make sure that loose or flammable objects are not in the area. 9. If you are deploying a steering wheel module, place the steering wheel module in the center of the space. 10. When deploying an IP module, refer to the following instructions: ^ Place the J 39401-B SIR deployment fixture (2) in the center of the cleared area. ^ Fill the deployment fixture with water or sand. ^ Mount the IP module (1) in the deployment fixture (2) with the vinyl/plastic trim facing up. ^ To mount, use 4 m 6 bolts (6), nuts (8), and washers (7) in order to properly secure the IP module (1) to the deployment fixture. ^ Securely tighten all fasteners prior to deployment. Page 7603 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 4693 Electrical Symbols Part 5 Page 1853 Electrical Symbols Part 2 Page 10617 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 10985 Tighten Tighten the nut to 48 N.m (35 lb ft). 10. Install the sealing washers. 11. Connect the compressor suction/discharge hose to the compressor (4). 12. Install the compressor suction/discharge hose washers. 13. Install the retaining nut (3). Tighten Tighten the nut to 33 N.m (24 lb ft). 14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the components using the J 39400. TrailBlazer EXT and the Envoy XL. TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor suction/discharge hose nut (3). 3. Remove the compressor suction/discharge hose from the compressor (4). 4. Remove the sealing washers. Page 15687 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4745 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4630 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 11798 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 13085 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 2932 Page 4785 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 748 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9482 C301 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 11795 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Service and Repair Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 7996 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Programming Theft Deterrent System Components Alarm Module: Service and Repair Programming Theft Deterrent System Components IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the procedure to setup a new theft deterrent control module must be performed prior to the 10 Minute Re-Learn Procedure. TOOLS REQUIRED Tech 2 diagnostic scan tool Procedure to setup a New Theft Deterrent Control Module Use this procedure only if replacing the theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Setup New VTD Module in the Vehicle Theft Deterrent, Special Functions data list. 4. Follow the scan tool on screen instructions. IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the module will learn keys immediately. The existing PCM however, must learn the new fuel continue password when the theft deterrent control module is replaced. - When replacing a powertrain control module (PCM) with a GM Service Parts Operation (SPO) Replacement Part, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, a relearn procedure must be performed to change this password again. A PCM which has been previously installed in another vehicle will have learned the fuel continue password of the other vehicles theft deterrent control module and will require performing the 10 Minute Re-Learn Procedure to learn the fuel continue password of the current vehicles theft deterrent control modules. - When performing the 10 Minute Re-Learn Procedure, all previously learned keys will be erased from the theft deterrent control module's memory. - Additional keys may be learned immediately after the 10 Minute Re-Learn Procedure. Refer to Adding Keys (Export). - When performing the 10 Minute Re-Learn Procedure, 2 master passkey III+ (PK3+) keys are required. If a gray valet key is learned first, the theft deterrent control module will not allow additional keys to be learned. TOOLS REQUIRED Tech 2 diagnostic scan tool - Techline Terminal with current Service Programming System (SPS) software 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: The passkey III+ (PK3+) keys - The theft deterrent control module - The PCM, see Important above IMPORTANT: If replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, insure the procedure to setup a new theft deterrent control module has been performed prior to the 10 Minute Re-Learn Procedure. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. With the scan tool, select Request Info. under Service Programming System and follow the scan tool on screen instructions. 3. Disconnect the scan tool from the vehicle and connect it to a Techline Terminal with current Service Programming System (SPS) software. 4. On the Techline Terminal, select Service Programming Systems and follow the Techline Terminal on screen instructions. 5. Disconnect the scan tool from the Techline Terminal and re-connect it to the vehicle. 6. With a master passkey III+ (PK3+) key, turn ON the ignition, with the engine OFF. 7. With the scan tool, select Program ECU under Service Programming System. 8. At this point the scan tool must remain connected for the duration of the 10 Minute Re-Learn Procedure. 9. Observe the SECURITY telltale or the scan tool on screen timer, after approximately 10 minutes the scan tool timer will expire and/or the telltale will turn off. The vehicle is now ready to relearn the key information and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition and wait 5 seconds. 11. With a master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the key transponder information and the PCM has now learned the fuel continue password. 12. Turn OFF the ignition and wait 15 seconds minimum. 13. With a second master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the second master passkey III+ (PK3+) key transponder information. 14. Learning Additional keys, if required. Refer to Adding Keys (Export). 15. With the scan tool, clear any DTCs. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the two halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. 4. Remove the battery. INSTALLATION PROCEDURE Page 3969 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 10946 8. Install the accumulator. 9. Recharge the refrigerant system. 10. Leak test the fittings of the components using the J 39400-A. TrailBlazer EXT, and Envoy XL Expansion (Orifice) Tube Replacement Tools Required ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. 2. Remove the accumulator. 3. Remove the coolant reservoir. 4. Loosen the evaporator tube nut (5) from the evaporator. 5. Remove the evaporator tube from the evaporator. 6. Remove the nut (2) from the evaporator tube block (3). 7. Separate the evaporator tubes at the block fitting (3). 8. Use the J 26549-E in order to remove the expansion tube (4). 9. Remove the O-ring seal and discard. 10. Remove the expansion tube from the evaporator tube (1). Drivetrain - Front Drive Axle Squeal/Squeak Seals and Gaskets: All Technical Service Bulletins Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the front brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. 6. Remove the front brake pads from the mounting bracket, inboard brake pad shown. 7. Inspect the brake hardware. Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft Coupler: Customer Interest Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 15916 Equivalents - Decimal And Metric Part 1 Page 12263 Disclaimer Page 12578 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 3244 Various symbols are used in order to describe different service operations. Page 2206 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 6813 1. Install new seals on the servo pistons and the servo cover. 2. Install the 2-4 servo assembly into the transmission. 3. Install the J29714-A. 4. Tighten the bolt in order to compress the servo cover. 5. Install the servo cover retaining ring. 6. Remove the J29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil pan bolt. ^ Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield. Notice: Refer to Fastener Notice in Service Precautions. Page 14401 1. Position the pad on the seat back frame. 2. Fit the seat back cover over the top of the seat back frame and pad. 3. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 4. Install the hog rings (1) to the cover and pad. 5. Pull the seat back cover down over the pad pressing the hook and loop fastener strips (2) together. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 4772 Electrical Symbols Part 6 Page 7262 Page 15462 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Locations Page 15458 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 1387 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 38 Page 15593 Brake Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15126 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 828 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. INSTALLATION PROCEDURE Page 6033 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Diagrams Compressor Clutch: Diagrams A/C Compressor Clutch Assembly - HVAC Systems - Manual A/C Compressor Clutch Assembly - HVAC Systems - Automatic Locations Locations View Page 7235 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 10228 1. Install the lower ball joint and J9519-E, J41435, and J45105-2 to the lower control arm. 2. Install the lower ball joint to the lower control arm using J9519-E, J41435, and J45105-2. 3. Remove J9519-E, J41435, and J45105-2 from the lower control arm. 4. Install J9519-E and J45105-1 to the lower ball joint. 5. Flare the lower ball joint flange using J9519-E and J45105-1. 6. Remove J9519-E and J45105-1 from the lower ball joint. 7. Install the steering knuckle with wheel hub and bearing attached. Install the tire and wheel. 9. Lower the vehicle. 10. Check the front wheel alignment. Page 7457 7. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 8. Remove the ABS sensor from the wheel hub and bearing. 9. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 10. Remove the wheel hub and bearing from the steering knuckle. 11. Remove the splash shield from the steering knuckle. Installation Procedure Page 6226 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 2517 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: Check the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. ^ Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 5265 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3113 Oil Pan: Specifications Oil Pan Bolt (Ends) 89 inch lbs. Oil Pan Bolt (Sides) 18 ft. lbs. Oil Pan Nut 18 ft. lbs. Oil Pan Stud 97 inch lbs. Page 11916 Page 6049 Various symbols are used in order to describe different service operations. Page 13610 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 4 retaining tabs are securly attached to the sill plate. 2. Align the retaining tabs to the liftgate door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Page 9761 Parts Information Parts are expected to be available 8-22-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 15448 Electrical Symbols Part 1 Page 14155 Tighten the sunroof module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the module. 4. Install the drive motor to the sunroof assembly. 5. With the aid of an assistant, install the sunroof assembly to the vehicle. Refer to Sunroof Replacement. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Page 15539 For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a Campaign Initiation Detail Report. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 15111 Electrical Symbols Part 2 Page 8267 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11715 Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 11212 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 239 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 5579 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 2482 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 796 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8658 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Locations Page 723 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Diagrams Engine Oil Level And Temperature Sensor Page 14670 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Rear Door Upper REMOVAL PROCEDURE Page 15919 Conversion - English/Metric Page 5973 Electrical Symbols Part 3 Page 5887 Conversion - English/Metric Page 867 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 4896 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. Page 10848 HVAC Control Module C1 Part 2 Page 4878 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1660 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Engine Controls - SES Lamp ON/ DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/ DTC's Set On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) # 04032 - (05/13/2004) 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 -Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the power train control module (PCM) on all affected vehicles as identified above including vehicles in new dealer inventory used inventory and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 9292 Electrical Symbols Part 2 Page 15802 5. Position the horizontal tab above the headliner and push the lens forward to seat the tab. 6. Push upward on the rear portion of the lens, in order to seat the rear lens retaining tab. 7. Pull down on the lens to ensure that the lens is secured to the headliner. Cigarette Lighter - Inoperative Cigarette Lighter: All Technical Service Bulletins Cigarette Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-016 Date: November, 2001 TECHNICAL Subject: Cigarette Lighter May Be Inoperative (Install New Lighter Element) Models: 2002 Buick LeSabre, Park Avenue, Rendezvous 2002 Cadillac DeVille, Seville 2001-2002 Chevrolet Cavalier 2002 Chevrolet Impala, Malibu 2002 Chevrolet Trans Sport (Export Only) 2002 Oldsmobile Alero, Aurora 2001-2002 Pontiac Sunfire 2002 Pontiac Bonneville, Grand Am 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Chevrolet and GMC 6-7H C-Series Conventional Medium Duty Models 2001-2002 Oldsmobile Bravada Condition Some customers may comment that the cigarette lighter is inoperative. Cause During the 2001 model year, a new style cigarette lighter element was put into production. Under certain conditions, when pushed in firmly, the cigarette lighter element may short to ground inside the receptacle. This condition may result in a blown fuse. Correction Install a new cigarette lighter element, P/N 11516140. Replace the fuse for the cigarette lighter, if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 9245 4. Install the A/C line bracket to the lift hook and secure the bracket with the bolt. Tighten Tighten the A/C line bracket bolt to 10 N.m (89 lb in). 5. Install the drive belt. 6. Connect the battery negative cable. Page 15423 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13705 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Service and Repair Radiator Support: Service and Repair Brace Replacement - Radiator Support Diagonal Removal Procedure 1. Remove the radiator air intake baffle. 2. Remove the headlamp housing panel. 3. Remove the hood latch support. 4. Remove the bolts that retain the battery tray brace to the body. 5. Remove the battery tray brace from the vehicle. 6. Remove the bolts that retain the radiator support diagonal brace to the radiator support. 7. Remove the radiator support diagonal brace from the vehicle. Installation Procedure 1. Install the radiator support diagonal brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the radiator support diagonal brace to the radiator support. Tighten the radiator support diagonal brace to 25 N.m (18 lb ft). Page 5313 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 3128 Electrical Symbols Part 7 Page 1647 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 10249 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 14956 Driver/Vehicle Information Display: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 10661 1. Remove the IP carrier. 2. Disconnect the electrical connector from the defroster actuator. 3. Remove the screws from the defroster actuator. 4. Remove the defroster actuator. INSTALLATION PROCEDURE 1. Install the defroster actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the defroster actuator screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the defroster actuator. 4. Install the IP carrier. Mode Actuator REMOVAL PROCEDURE Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter and Bypass Valve Assembly Replacement Removal Procedure 1. Remove the oil filter. 2. Remove the oil filter adapter. 3. Remove the oil filter bypass valve. Installation Procedure 1. Install the oil filter bypass valve. Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Assembly to Case Bolt ......................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 4647 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 12347 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 12681 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10353 5. Disconnect the air spring compressor electrical connection (2). Important: Ensure the color on air supply lines match the color on the air spring compressor for reassembly. 6. Disconnect the air supply lines (3) from the air spring compressor (1). 7. Remove the air spring compressor from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Check the air supply lines for deep scores or cuts. If the air supply lines are damage the lines must be replaced. 1. If no damage to the air supply pipes is evident, then remove the fittings from the new compressor and use existing fittings that are already attached to air supply lines. Install the air supply lines with existing fittings to the air spring compressor. Tighten the air supply line fittings to 2.25 Nm (18.5 lb in). 2. If damage is evident to the air supply lines, then replace the air supply lines. Page 3900 Electrical Symbols Part 5 Page 13608 Scuff Plate: Removal and Replacement Door Sill Plate Replacement - Front Door Sill Plate Replacement - Front Removal Procedure 1. If removing the right sill plate, remove the right insulator panel. Refer to Closeout/Insulator Panel Replacement - Right 2. Starting at the rear of the sill plate, use a flat-bladed tool in order to release the 5 retaining tabs. 3. If removing the left sill plate, remove the sill plate from the hood release handle. 4. Remove the sill plate from the door frame. 5. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 5 retaining tabs are securely attached to the sill plate. 2. If installing the left sill plate, position the hood release handle through the sill plate. 3. Align the retaining tabs to the door frame slots. 4. Starting at the front of the sill plate, push down on the sill plate, seating the retaining tabs to the door frame. 5. If installing the right sill plate, install the right insulator panel. Refer to Closeout/Insulator Panel Replacement - Right. Door Sill Plate Replacement - Rear (TrailBlazer, Envoy, Bravada) Door Sill Plate Replacement - Rear (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure Page 14053 Power Seat Control Module: Locations Locations View Page 120 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 4615 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 11691 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Air Distribution Ducts Replacement - Auxiliary (Lower) Air Duct: Service and Repair Air Distribution Ducts Replacement - Auxiliary (Lower) REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the lower air duct fastener (4). 3. Remove the mid-upper air distribution fastener (6). 4. Remove the mid-upper air distribution duct (6). 5. Remove the lower air duct (5) from the vehicle. INSTALLATION PROCEDURE 1. Install the mid-upper air distribution duct (6). 2. Install the mid-upper air distribution fastener (7). NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the mid-upper air distribution screw. Tighten Tighten the screw to 1.9 N.m (17 lb in). 4. Install the lower air duct (5) to the vehicle. Tighten Tighten the screw to 1.9 N.m (17 lb in). Page 5668 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the Underhood Compartment above the left front wheel well. Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Remove the rear hood seal from the inlet grille panel studs. 3. Remove the seal from the inlet grille panel. Installation Procedure 1. Position the seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Close the hood. Specifications Parking Brake Cable: Specifications Park Brake Cable Attaching Nuts 12.6 ft. lbs. Page 2375 Drive Belt Vibration Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 12350 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 5051 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9926 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 5780 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Interior - Power Memory Seat Inoperative Power Seat Control Module: Customer Interest Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 970 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 3483 Radiator Cooling Fan Motor: Specifications Cooling Fan Hub Nut 41 ft. lbs. Page 9542 For vehicles repaired under warranty use the table shown. DISCLAIMER Bose(R) Premium Sound With Rear Audio Controls These vehicles use wiring harness P/N 15164931. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconned the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). Page 5111 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4698 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8678 Page 4324 Electrical Symbols Part 6 Page 9308 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 15313 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12173 Equivalents - Decimal And Metric Part 1 Page 2115 Disclaimer Page 14079 Locations View Page 9014 Installation Procedure 1. Install the reservoir on the master cylinder, if needed. 2. Fill the master cylinder reservoir with brake fluid. 3. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding. 4. Install the master cylinder to the vehicle. Page 10852 Control Assembly: Diagrams HVAC Systems - Automatic HVAC Control Module C1 Part 1 Page 14748 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3390 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 15272 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 15739 Conversion - English/Metric Page 10759 Auxiliary Blower Motor: Connector Views Blower Motor - Auxiliary (Body Type VIN 6) Blower Motor - Auxiliary (Body Type VIN 3) Page 8234 Seals and Gaskets: Service and Repair Transfer Case Output Shaft Seal Replacement- Rear Transfer Case Output Shaft Seal Replacement- Rear ^ Tools Required J 37668-A Output Shaft Seal Installer (4401 & 4470 Transfer Case) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Installation Procedure 1. Align the rear output shaft seal. 2. Using the J 37668-A, install the rear output shaft seal. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 5204 Oxygen Sensor: Locations Locations View Page 10749 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 8845 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15752 Glove Box Lamp: Description and Operation The inadvertent power courtesy lamps supply voltage circuit of the BCM also provides battery positive voltage to instrument panel compartment lamp. When the IP compartment is opened, a switch closes to provide a ground circuit and the IP compartment lamp illuminates. Page 14829 Electrical Symbols Part 6 Page 12172 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8587 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 752 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 6965 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 11201 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint Systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: ^ Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people Of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. ^ Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. ^ Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. ^ Replace any seat belt system if you are doubtful about Its condition. This not only Includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been In a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 3870 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 718 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 1021 Page 11790 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 10204 Steering Wheel: Specifications Steering Wheel Shroud Retaining Screws 18 inch lbs. Steering Wheel to Steering Shaft Retaining Nut 30 ft. lbs. Page 9852 22. Remove the screws retaining the IP bezel to the IP and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the dash, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 27. With both of the green connectors and the first breakout of four wires in hand, insert the new wiring harness from under the IP up to the radio area of the IP, where the radio is normally positioned. 28. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 29. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 30. Disconnect the mechanics wire from the speaker wires, connect the speaker wires to the speaker and fasten the speaker to the IP. 31. Repeat the last three steps for the right speaker. 32. Remove the CPA from the radio connector, remove the wires shown below from the radio connector and replace them with the wires from the new wiring harness. ^ Remove wire in cavity B9 and insert the Brown wire. ^ Remove wire in cavity B8 and insert the Brown/White wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Blue wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminal from the wires you just removed from the connector. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet to the area of the rear audio control, and reposition the carpeting. 35. Remove the CPA from the rear audio control connector and remove four wires from the Rear Audio Control in-line harness connector and replace them with the wires from the new harness as listed below. ^ Remove wire in cavity B3 and insert the Brown wire. ^ Remove wire in cavity A8 and insert the Brown/White wire. ^ Remove wire in cavity A9 and insert the Blue wire. ^ Remove wire in cavity A1 and insert the Black wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires of the original harness, as close to the taped portion of the harness as possible. 36. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 37. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 38. Route the new harness under the carpet from the rear of the console to the 8-way connector. 39. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE Locations Locations View Page 9054 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Locations Locations View Specifications Power Steering Line/Hose: Specifications Power Steering Hose Assembly to the 7 ft. lbs. Frame Brackets Mounting Bolts Power Steering Hose Assembly to the 7 ft. lbs. Front Crossmember Bracket Mounting Bolt Power Steering Hose Assembly to the 9 ft. lbs. Power Steering Gear Retaining Bolt Power Steering Hose Assembly (Pressure Hose) to 18 ft. lbs. the Power Steering Pump Power Steering Hose Assembly to the Wheel Well 7 ft. lbs. Bracket Mounting Bolt Specifications Pinion Bearing: Specifications Front Drive Axle Pinion Bearing Preload (New Bearings) ............................................................................................................................... 1.7-3.4 Nm (15-30 inch lbs.) Pinion Bearing Preload (Used Bearings) .............................................................................................................................. 1.1-2.8 Nm (10-25 inch lbs.) Pinion and Differential Case Bearing Preload (New Bearings) ............................................................................................. 3.4-6.2 Nm (30-55 inch lbs.) Pinion and Differential Case Bearing Preload (Used Bearings) ........................................................................................... 2.8-5.6 Nm (25-50 inch lbs.) Rear Drive Axle Bearing Cap Bolts ................................................................................................................................ ................................................. 75 Nm (55 ft. lbs.) Pinion and Differential Case Bearing Preload, New Bearings ............................................................................................. 3.4-6.2 Nm (30-55 inch lbs.) Pinion and Differential Case Bearing Preload, Used Bearings ............................................................................................. 2.8-5.6 Nm (25-50 inch lbs.) Pinion Bearing Preload, New Bearings ................................................................................................................................ 1.7-3.4 Nm (15-30 inch lbs.) Pinion Bearing Preload, Used Bearings ................................................................................................................................ 1.1-2.8 Nm (10-25 inch lbs.) Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the 5 bolts securing the heat shield to the floor panel studs. 3. Remove the heat shield from the vehicle. Installation Procedure 1. Place the catalytic converter heat shield onto the floor panel studs. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure the heat shield with the 5 bolts. ^ Tighten the catalytic converter heat shield bolts to 7 Nm (62 inch lbs.). 3. Lower the vehicle. Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Blower Motor Control Processor Replacement Control Module HVAC: Service and Repair Blower Motor Control Processor Replacement REMOVAL PROCEDURE 1. Remove the right closeout panel. 2. Disconnect the electrical connector from the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor mounting screws (1). 5. Remove the blower motor control processor (2:). INSTALLATION PROCEDURE 1. Install the blower motor control processor (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor mounting screws (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector to the blower motor. 5. Install the right closeout panel. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 398 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1665 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 4332 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 13910 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 4245 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 343 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 2367 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Page 1711 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6742 3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic. 4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3). 5. Install the washer and snap ring retaining the motor/encoder rotary position sensor. 6. Install the motor/encoder gasket (1). Page 8345 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 3620 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 6406 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Trailblazer, Envoy, and Bravada Amplifier: Service and Repair Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the upper right quarter trim panel. 2. Remove the lower right quarter trim panel. 3. Disconnect the electrical connectors from the radio speaker amplifier. 4. Remove the 4 bolts that retain the radio speaker amplifier to the body. 5. Remove the radio speaker amplifier from the body. INSTALLATION PROCEDURE 1. Install the radio speaker amplifier to the body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 bolts that retain the radio speaker amplifier to the body. Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connectors to the radio speaker amplifier. 4. Install the lower right quarter trim panel. 5. Install the upper right quarter trim panel. Page 14373 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Rear No. 2 REMOVAL PROCEDURE 1. Remove the head restraint assembly. 2. Remove the extension panel hinge trim (2). 3. Remover the screws (3) securing the extension panel (1) to the seat back. 4. Remove the J-strip (1) from the seat adjuster cross bar (2). Page 3026 Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Programming Theft Deterrent System Components Alarm Module: Service and Repair Programming Theft Deterrent System Components IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the procedure to setup a new theft deterrent control module must be performed prior to the 10 Minute Re-Learn Procedure. TOOLS REQUIRED Tech 2 diagnostic scan tool Procedure to setup a New Theft Deterrent Control Module Use this procedure only if replacing the theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Setup New VTD Module in the Vehicle Theft Deterrent, Special Functions data list. 4. Follow the scan tool on screen instructions. IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the module will learn keys immediately. The existing PCM however, must learn the new fuel continue password when the theft deterrent control module is replaced. - When replacing a powertrain control module (PCM) with a GM Service Parts Operation (SPO) Replacement Part, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, a relearn procedure must be performed to change this password again. A PCM which has been previously installed in another vehicle will have learned the fuel continue password of the other vehicles theft deterrent control module and will require performing the 10 Minute Re-Learn Procedure to learn the fuel continue password of the current vehicles theft deterrent control modules. - When performing the 10 Minute Re-Learn Procedure, all previously learned keys will be erased from the theft deterrent control module's memory. - Additional keys may be learned immediately after the 10 Minute Re-Learn Procedure. Refer to Adding Keys (Export). - When performing the 10 Minute Re-Learn Procedure, 2 master passkey III+ (PK3+) keys are required. If a gray valet key is learned first, the theft deterrent control module will not allow additional keys to be learned. TOOLS REQUIRED Tech 2 diagnostic scan tool - Techline Terminal with current Service Programming System (SPS) software 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: The passkey III+ (PK3+) keys - The theft deterrent control module - The PCM, see Important above IMPORTANT: If replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, insure the procedure to setup a new theft deterrent control module has been performed prior to the 10 Minute Re-Learn Procedure. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. With the scan tool, select Request Info. under Service Programming System and follow the scan tool on screen instructions. 3. Disconnect the scan tool from the vehicle and connect it to a Techline Terminal with current Service Programming System (SPS) software. 4. On the Techline Terminal, select Service Programming Systems and follow the Techline Terminal on screen instructions. 5. Disconnect the scan tool from the Techline Terminal and re-connect it to the vehicle. 6. With a master passkey III+ (PK3+) key, turn ON the ignition, with the engine OFF. 7. With the scan tool, select Program ECU under Service Programming System. 8. At this point the scan tool must remain connected for the duration of the 10 Minute Re-Learn Procedure. 9. Observe the SECURITY telltale or the scan tool on screen timer, after approximately 10 minutes the scan tool timer will expire and/or the telltale will turn off. The vehicle is now ready to relearn the key information and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition and wait 5 seconds. 11. With a master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the key transponder information and the PCM has now learned the fuel continue password. 12. Turn OFF the ignition and wait 15 seconds minimum. 13. With a second master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the second master passkey III+ (PK3+) key transponder information. 14. Learning Additional keys, if required. Refer to Adding Keys (Export). 15. With the scan tool, clear any DTCs. Page 173 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 5075 Electrical Symbols Part 1 Page 488 Locations View Page 5847 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 5691 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 9215 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 2622 Fuse Block - Rear C2 Part 2 Page 15646 For vehicles repaired under warranty, use the table. Disclaimer Page 14967 Electrical Symbols Part 6 Page 5791 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 11538 1. Install the antenna mast to the antenna base. NOTE: Refer to Fastener Notice in Service Precautions. 2. Screw the antenna mast to the antenna base. Tighten Tighten the antenna mast to 5 N.m (44 lb in). Page 13892 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Locations Locations View Fuse Block - Rear Locations View Page 13339 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9210 Electrical Symbols Part 5 Page 13578 16. If the vehicle is equipped with a sunroof, seat the 6 interlocking strips. 17. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 18. Install the center pillar headliner harness electrical connector to the bussed electrical center, and the block base to the floor panel. 19. Install the headliner harness retaining clips (2) to the rocker panel and the floor panel. 20. Install the headliner harness to the left center pillar. 21. Install the following headliner harness clips to the center pillar: Page 3614 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Audio/A/C - Settings Change While Driving Body Control Module: All Technical Service Bulletins Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4353 Crankshaft Position (CKP) Sensor Page 9932 Page 2972 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 7118 Shift Cable: Specifications Shift Cable Grommet Screw ................................................................................................................ ................................................. 1.7 Nm (15 inch lbs.) Shift Control Cable Attachment ....................... ......................................................................................................................................... 20 Nm (15 ft. lbs.) Page 6020 Electrical Symbols Part 4 Page 60 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 7059 Page 544 Locations View - HVAC Systems - Automatic Page 648 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Diagrams Door Lock Cylinder Switch - Driver Page 3937 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 15223 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Page 7159 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 23458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 12323 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 10867 1. Connect the rear HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 15071 Page 3384 1. Install the air cleaner element (1) onto the air cleaner outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element and air cleaner outlet duct into the lower air cleaner housing/washer solvent tank assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the air cleaner cover/resonator assembly (1). Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator support cover. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Page 10708 Ambient Air Temperature Sensor Page 2783 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 9581 For vehicles repaired under warranty use the table shown. DISCLAIMER Bose(R) Premium Sound With Rear Audio Controls These vehicles use wiring harness P/N 15164931. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconned the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). Page 5425 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Page 2950 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement ^ Tools Required J 36660-A Torque Angle Meter - J 41478 Crankshaft Front Oil Seal Replacement - J 41816-2 Crankshaft End Protector - J 44226 Crankshaft Balancer Remover/Holder Removal Procedure 1. Remove the radiator intake baffle. 2. Remove the grill. Important: When removing the diagonal brace, only remove the one bolt from the battery tray brace that is bolted to the radiator brace. 3. Remove the radiator support diagonal brace. 4. Remove the hood latch support. 5. Remove the cooling fan and shroud. 6. Remove the drive belt. 7. Carefully loosen and remove the balancer bolt. 8. Install J41816-2 into the end of the crankshaft. Important: Do not pull on outer edge of the crankshaft balancer. 9. Using the J 44226 remove the balancer. 10. Remove J44226 and J41816-2. 11. Remove the crankshaft balancer shim from the crankshaft snout. 12. Clean and inspect the crankshaft balancer. Installation Procedure Page 13318 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 3172 DISCLAIMER Front Wheel Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Bearing Replacement Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the brake rotor. 6. Disengage the wheel drive shaft from the wheel hub and bearing. Place a brass drift against the outer end of the wheel drive shaft in order to protect the wheel drive shaft threads. Sharply strike the brass drift with the hammer. Do not attempt to remove the wheel drive shaft from the wheel hub and bearing at this time. Recall 02V121000: Fuel Filter Connector Replacement Fuel Line Coupler: All Technical Service Bulletins Recall 02V121000: Fuel Filter Connector Replacement DEFECT: On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. REMEDY: Dealers will replace the fuel filter quick connect retainers. The manufacturer has reported that owner notification began May 20, 2002. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 4414 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Engine Controls - Underhood Ticking Noise Fan Clutch: All Technical Service Bulletins Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 2584 Refrigerant Oil: Service and Repair Compressor Oil Balancing DRAINING PROCEDURE IMPORTANT: Drain and measure as much of the refrigerant oil as possible from the removed compressor. 1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean, graduated container. Rotate the compressor shaft to assist in draining the compressor. 2. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor. 3. Properly discard the used refrigerant oil. BALANCING PROCEDURE IMPORTANT: The refrigerant oil in the A/C system must be balanced during compressor replacement. 1. The replacement compressor is shipped with 74 ml (2.5 oz) of refrigerant oil. 2. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is: ^ Less than 74 ml (2.5 oz) Leave the 74 ml (2.5 oz) in the replacement compressor. ^ More than 74 ml (2.5 oz) Add to the compressor the difference between the 74 ml (2.5 oz) and the amount drained. Page 13490 4. Remove the front door sill plates. 5. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 6. Remove the center pillar trim panels. 7. Remove the lift gate door sill plate. 8. Remove the left/right front body side window garnish molding. 9. Remove the left/right rear body side window garnish molding. 10. Remove the bolts from the cargo tie-down loops. 11. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 12. Loosen the three bolts that secure the jack carrier to the vehicle. 13. Remove the carpet from around the wheel stud. 14. Remove the body electrical block. 15. Remove the body electrical block electrical connectors back through the hole in the carpet. 16. Pull the communication interface module electrical connectors back through the hole in the carpet. 17. Remove the floor console to the floor console carrier. 18. Remove the 4 nuts (2) retaining the rear of the floor console bracket to the floor weld studs. 19. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 20. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. Page 9626 Locations View Page 11630 1. If installation of the mounting bracket is required, install the mounting bracket to the overhead console. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 OnStar(R) microphone retaining screws. Tighten Tighten the screws to 0.8 N.m (7 lb in). 3. Install the microphone to the mounting bracket ensuring the quick release tab (1) is fully seated. 4. Connect the electrical connector to the OnStar(R) microphone (1). 5. Install the overhead console. Page 14129 Sun Shade: Technical Service Bulletins Body - Moonroof Sunshade Damage Prevention File In Section: 08 - Body and Accessories Bulletin No.: 02-08-110-005 Date: October, 2002 INFORMATION Subject: Avoiding Sunshade Damage During Removal And Installation Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Sunshades are being replaced in the field when not necessary because they are being damaged during the removal and installation process. Many sunshades are being reinstalled improperly during repairs to the overhead system causing the sunshades to be loose or fall out. The Sunshade Replacement procedure in SI (Document ID # 740348) has been revised to help reduce the number of cases of damage to the sunshades during removal and installation. Do not pry or use excessive force to remove the sunshades as this may damage the roof sheet metal at the sunshade attaching point. If necessary, straighten the roof sheet metal before reinstalling the sunshade. If the sheet metal is bent, it will result in a sunshade that is loose or it may fall out Warranty Information DISCLAIMER Page 10292 12. Remove the lower ball joint retaining nut. 13. Remove the steering knuckle from the lower control arm using J43631. 14. Remove the steering knuckle from the vehicle. Installation Procedure 1. Install the steering knuckle to the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower ball joint retaining nut. Tighten the lower ball joint retaining nut to 110 Nm (81 ft. lbs.). Page 9373 Fuse Block - Underhood C4 Page 5996 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Locations Locations View Page 14335 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 15778 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1222 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Right REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2) INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Page 4864 Electrical Symbols Part 8 Page 1735 Electrical Symbols Part 1 Page 2640 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 9644 Fuse Block - Rear C2 Part 1 Page 12339 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 14468 1. Lift the seat cushion to expose the seat riser latch assembly (2). 2. Remove the seat riser latch assembly (2) from the outer riser assembly stud (1). 3. Remove the seat riser latch assembly (1) from the seat latch rod (2). INSTALLATION PROCEDURE 1. Install the seat riser latch assembly (1) to the seat latch rod (2). Page 4179 Electrical Symbols Part 5 Page 5704 Conversion - English/Metric Page 2829 Wheel Fastener: Specifications Wheel Nut 103 ft. lbs. Page 1476 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1745 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4125 Disclaimer Page 2872 1. Install the exhaust camshaft actuator into the timing chain. 2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator sprocket (1). Important: Ensure the alignment pin is engaged between the camshaft and the exhaust camshaft position actuator. 3. Install the exhaust camshaft actuator onto the exhaust camshaft. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Notice: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. Important: Ensure the camshaft actuator is rotated clockwise relative to the camshaft prior to tightening the bolt. Do not force the camshaft actuator to rotate clockwise. If it does not move easily, it is already fully advanced. New camshaft actuators are already packaged in the fully advanced (clockwise) position. 4. Install the exhaust camshaft actuator bolt. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 lb ft). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. 5. Remove the J-44217. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 6431 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Page 8641 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8671 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Page 7338 Differential Carrier: Specifications Front Drive Axle Differential Carrier Assembly Case Bolts ............................................................................................................................................. 48 Nm (35 ft. lbs.) Differential Carrier Assembly Mounting Bolts ..................................................................................................................................... 85 Nm (63 ft. lbs.) Page 10405 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: The rear axle must not be allowed to hang freely while servicing rear suspension components. Not supporting the rear axle will result in damage to the upper control arm and/or to the air suspension components. 2. Support the rear axle. 3. Remove the shock absorber upper mounting bolt. 4. Remove the shock absorber lower mounting bolt. 5. Remove the shock absorber from the vehicle. Installation Procedure Page 3351 Fuel System Diagnosis - Steps 18-22 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, then an internal loss of pressure is indicated. 7. This step inspects the fuel pressure regulator for a fuel leak from the atmospheric vent. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 8. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 9. This step tests for a leaking fuel injector or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 12. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 14. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 16. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Page 6109 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 5723 Electrical Symbols Part 1 Page 12946 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 7267 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 1749 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 2201 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 759 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15742 Cornering Lamp: Description and Operation The turn signal switch sends battery positive voltage to the cornering lamps which will constantly remain illuminated until turn signal operation is cancelled. The cornering lamps are grounded at G103 and G107. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 15676 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 14669 Rear Door Weatherstrip: Service and Repair Rear Door Opening REMOVAL PROCEDURE 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Page 4423 Conversion - English/Metric Page 5605 7. Remove the fuel rail attaching bolts. NOTE: ^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. 8. Remove the fuel rail assembly. 9. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3). 10. Discard the O-ring seals. 11. If the fuel rail is not being replaced, go to the Installation Procedure. DISASSEMBLY PROCEDURE 1. Remove the fuel injectors. 2. Remove the fuel pressure regulator. 3. Remove the fuel injector harness from the fuel rail. ASSEMBLY PROCEDURE 1. Install the fuel injector harness to the fuel rail. 2. Install the fuel pressure regulator. 3. Install the fuel injectors. INSTALLATION PROCEDURE Page 5864 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 1316 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4026 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 7780 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14463 2. Install the release latch to the seat frame by pressing the latch into the seat frame until the locking tabs are fully engaged. 3. Install the seat back cover and pad. Seat Back Latch Bracket - Rear REMOVAL PROCEDURE 1. Remove the seat back from the vehicle. 2. Remove the bolts (2) that retain the latch bracket to the seat hinge. 3. Remove the latch bracket from the seat hinge. INSTALLATION PROCEDURE Page 5746 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 15347 Electrical Symbols Part 8 Page 3838 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 5798 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 10929 Disclaimer Page 8670 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 14858 Cigar Lighter Page 5680 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Inflatable Restraint Side Impact Module Replacement Front Side Air Bag: Service and Repair Inflatable Restraint Side Impact Module Replacement - Front INFLATABLE RESTRAINT SIDE IMPACT MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE CAUTION: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: ^ The seat cushion frame ^ The seat recline, if equipped ^ The seat adjuster ^ The seat back frame Failure to do so may cause future personal injury. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the seat assembly from the vehicle. 3. Remove the seat trim panel. 4. Remove the seat back cover and pad. 5. Remove the front seat back panel. 6. Remove the push pin (2) securing the top of the seat belt retractor assembly to the seat back frame. 7. Remove the 2 screws (1) that secure the inflatable side impact module to the seat back frame. 8. Disconnect the SIR wiring harness from the module. 9. Remove the side impact module. 10. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to Inflator Module Handling and Scrapping. Page 13691 Electrical Symbols Part 5 Page 3175 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil pressure switch. ^ Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Diagram Information and Instructions Tachometer: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 4514 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Page 12306 Page 5725 Electrical Symbols Part 3 Page 11772 Disclaimer Page 7823 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11139 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Left REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Page 4618 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 6909 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Page 9209 Electrical Symbols Part 4 Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 15418 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 7899 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 14435 1. Install the small loop (1) onto the rear seat cushion latch (2). 2. Install the strap through the opening in the seat pan. 3. Install the rear-seat cushion cover and the pad. 4. Install the rear seat cushion assembly to the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Cover and Pad Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Tools Required J 36796Clip Removal Tool Removal Procedure 1. Remove the seat cushion from the vehicle. 2. Remove the seat cushion bracket. 3. Remove the seat latch bezels. 4. Use the J 36796 to remove the push pins (1) on the underside of the seat bottom, in order to start the seat cushion removal procedure. 5. Fold the carpet back in order to release the J-strips that retain the cover to the seat pan. 6. Starting at either forward corner, compress the foam and partially remove the seat cover assembly from the seat pan. Important: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. Page 9592 38. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 39. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 40. Reinstall the rear electrical center cover. 41. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate, and install the retainers. 42. Reinstall the knee bolster (TrailBlazer). 43. Reinstall the left side closeout/insulator panel (TrailBlazer). 44. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 45. Reinstall the console to the vehicle and install the retainers. 46. Reinstall the shift boot and handle assembly. 47. Reinstall the console bin and retainers. 48. Reinstall the first lock pillar trim and carpet retainers to both door openin9s. 49. Position the drivers seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 50. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 51. Connect the Tech 2(R) and clear codes. Page 245 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 11620 Passlock Sensor Page 5080 Electrical Symbols Part 6 Page 998 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Page 14734 Electrical Symbols Part 3 Interior - Headliner Sags at Rear of Sunroof Headliner: All Technical Service Bulletins Interior - Headliner Sags at Rear of Sunroof File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-004 Date: May, 2002 TECHNICAL Subject: Headliner Sag at Rear of Sunroof Opening (Replace Velcro(R) Patches) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the headliner sags at the rear of the sunroof opening. Cause The Velcro(R) patches on the underside of the sunroof module may have been installed off location. The Velcro(R) patches on the sunroof module and the headliner may not align. Correction 1. Carefully pull down the headliner at the rear of the sunroof opening and verify the alignment between the Velcro(R) patches on the sunroof module and the headliner. 2. If the patches are misaligned, insert a small block of wood between the roof and the headliner in order to provide access to the patches. 3. Remove the patches on the sunroof module. 4. Clean the surface of the sunroof module using one the cleaners listed below. 5. Install two new Velcro(R) patches, from the service kit (P/N 88952325), on the sunroof module making sure the patches are properly aligned with the headliner patches. 6. Remove the block of wood and push the headliner back in place so that the Velcro(R) patches are fully engaged. Cleaners ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Parts Information Parts are currently available from GMSPO. Warranty Information Page 7134 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 9513 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 5330 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 4289 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11397 1. Install the seat belt buckle to the seat assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut (1) which retains the seat belt buckle to the seat assembly. Tighten Tighten the front seat belt buckle nut to 52 N.m (38 lb ft). 3. Connect the seat belt reminder wiring harness (3) on the driver's seat. 4. Install the front seat assembly. Page 4258 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Ride/Trim Height Inspection Procedure Alignment: Service and Repair Ride/Trim Height Inspection Procedure TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following prior to measuring trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement - Front The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the high and the low measurements. Cross vehicle Z heights should be within 24 mm (0.9 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage. D Height Measurement - Rear The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. Page 4012 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 13936 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1423 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9476 C101 Part 2 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes C104 Part 1 Page 12515 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 15668 Electrical Symbols Part 6 Page 5918 Ignition Coil: Description and Operation Each ignition coil has an ignition 1 feed and a ground. The PCM supplies an ignition control (IC) circuit. Each ignition coil contains a solid state driver module as its primary element. The PCM signals the coil driver to initiate a firing event by applying the IC circuit voltage for the appropriate time or dwell. When the voltage is removed, the coil fires the spark plug. The coils are current-limited to prevent overloading if the IC current is held high too long. The spark plugs are tipped with platinum for long wear and higher efficiency. Page 6587 Disclaimer Page 4617 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 1800 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10582 Locations View - HVAC Systems - Manual Page 4349 Equivalents - Decimal And Metric Part 1 Page 2680 Vehicle Lifting Points 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center Page 14963 Electrical Symbols Part 2 Page 5282 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8832 Electrical Symbols Part 7 Service and Repair Seat Bottom Frame: Service and Repair SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1, 4), and remove the SIR harness from the seat. 8. Remove the seat harness from the seat pan. 9. Remove the seat memory module, if equipped. 10. Remove the seat cushion assembly. 11. Remove the seat cushion cover and pad from the seat frame. 12. Remove the wiring harness and connector clips, if you are replacing the frame. INSTALLATION PROCEDURE Page 13642 Installation Procedure 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Connect the wiring harness connector to the auxiliary power outlet. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the five screws that the retain the rear quarter trim panel to the body. Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 6. Install the seat belt lower anchor. Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 7. Install the right rear door sill panel. 8. Install the liftgate sill plate. 9. Install the right body side window forward garnish molding. 10. Install the right body side window rear garnish molding. 11. Return the third row seats to the upright position. 12. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Right (TrailBlazer, Envoy, Bravada) Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the cargo shade/cover. 2. Remove the inflator access panel. 3. Remove the right rear quarter upper trim panel. 4. Remove the liftgate sill plate. 5. Remove the right rear door sill panel. 6. Remove the lower seat belt anchor bolt. 7. Release the retaining clips that retain the trim panel to the body. Locations Locations View Page 11283 49. Connect the deployment harness to the IP module connector. 50. Route the deployment harness out of the passenger side of the vehicle. 51. Completely cover the windshield and the front door openings with a drop cloth. 52. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length. 53. Deploy each deployment loop one at a time. 54. Place a power source, 12 V minimum or a 2 A minimum, i.e., a vehicle battery, near the shorted end of the harnesses. 55. Separate one set of wires and touch the wire ends to the power source in order to deploy the inflator modules, doing only one inflator module at a time. 56. Disconnect the deployment harness from the power source and twist the wire ends together. 57. Continue the same process with the remaining deployment harnesses that are available. 58. Remove the drop cloth from the vehicle. 59. Disconnect all harnesses from the vehicle. 60. Discard the harnesses. 61. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 62. If one or more of the inflator modules did not deploy, perform the following steps to remove the undeployed modules from the vehicle. ^ If the steering wheel module did not deploy, refer to Inflatable Restraint Steering Wheel Module Replacement. ^ If the IP module did not deploy, refer to Inflatable Restraint Instrument Panel Module Replacement. ^ If the side impact module-left did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Front. 63. Call the Technical Assistance Group for further assistance. Page 11271 19. Separate the 2 banana plugs on the SIR deployment harness. 20. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made. 21. Disconnect the SIR deployment harness from the power source after the inflator module deploys. CAUTION: Refer to SIR Deployed Inflator Modules Are Hot Caution in Service Precautions. Page 10074 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 10146 For vehicles repaired under warranty, use the table. Disclaimer A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 14183 1. Install the cover to the head restraint. 2. Install the J-strips on the bottom of the head restraint cover. 3. Install the front seat head restraint. Head Restraint Replacement - Rear Seat Head Restraint Replacement - Rear Seat Removal Procedure 1. Raise the head restraint to the full up position. 2. Adjust the seat cushion just below the top of the seat back in order to gain access to the retaining clip on each head restraint post. 3. Remove the retaining clip from each head restraint post. 4. Remove the head restraint from the seat back. Installation Procedure 1. Install the retaining clips to the head restraint retractor. Page 14174 3. Remove the cover from the head restraint. INSTALLATION PROCEDURE 1. Install the cover to the head restraint. 2. Install the J-strips on the bottom of the head restraint cover. Page 13532 1. Position the rear console to the roof panel ensuring the screw holes are indexed properly. 2. Partially install the 4 screws that retain the rear console to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 screws retaining the rear console to the roof panel. Tighten the screws to 1.2 N.m (10 lb in). Roof Console Retainer Replacement Roof Console Retainer Replacement Removal Procedure 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT, Envoy XL) Headliner Replacement (Trailblazer, Envoy, Bravada). 2. Remove the 4 screws securing the console retainer to the Z clips. 3. Remove the roof retainer from the vehicle. 4. If replacing the roof retainer, remove the Z clips from the roof panel. Installation Procedure 1. If replacing the roof retainer, install the roof retainer the roof panel ensuring the Z clips are fully seated. 2. If installing the existing roof retainer, position the roof retainer to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Partially install the 4 screws retaining the roof retainer to the Z clips. Tighten the roof retainer attachment screws to 1.2 N.m (10 lb in). 4. Install the headliner. A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 1639 Electrical Symbols Part 3 Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 11048 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 1802 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 12361 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 8974 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result In serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. 5. Remove the piston seal from the caliper bore. Do not use a metal tool. Page 12421 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 11959 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 5211 Electrical Symbols Part 4 Page 515 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 6726 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 5943 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1789 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 7748 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 3711 1. Install the thermostat housing at the water inlet to the engine block. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat housing bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 3. Lubricate the inner diameter of the radiator hose with engine coolant. 4. Install the outlet hose to the thermostat (1). Secure the hose with the clamp. 5. Fill the cooling system with specified coolant and concentration. 6. Inspect all sealing surfaces for leaks after starting the engine. Page 14616 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9010 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder Replacement. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder Reservoir Replacement. 7. Using a smooth, round-ended fool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated filtered air into the front outlet port in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore. inlet and outlet ports, the secondary piston (1). and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated. filtered air. 4. Lubricate the master cylinder bore the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme 11, GM U.S. P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder Reservoir Replacement. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement. Page 15518 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9041 10. Install the park brake retaining bracket bolt in the frame. ^ Tighten park brake cable retaining bracket bolt to 20 Nm (15 ft. lbs.). 11. Install the park brake cable to the park brake cable retainers, left rear shown. 12. Install the shield for the fuel tank. Page 12685 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 9432 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 11302 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) Part 1 Page 10844 Control Assembly: Locations HVAC Systems - Automatic Locations View - HVAC Systems - Automatic Specifications Sensor Resistance Table - HVAC Systems - Automatic Page 11404 1. Install the seat belt side buckle (1) to the seat with the seat belt anchor nut (2). Tighten Tighten the seat belt side buckle nut to 55 N.m (40 lb ft). 2. Install the inboard rear seat back cushion latch cover with 3 screws. Tighten Tighten the rear seat back cushion latch cover screws to 2 N.m (18 lb in). Page 400 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12867 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Page 4796 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 2256 Wiper Switch: Diagrams Rear Window Wiper/Washer Switch Windshield Wiper Washer Switch (Multifunction Switch C3) Page 9643 Fuse Block - Rear C1 Part 2 Page 3138 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11693 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 12316 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 3025 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Page 9233 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Testing and Inspection Mirror Memory Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Doors; Testing and Inspection. Page 6524 For vehicles repaired under warranty, use the table. Disclaimer Page 4978 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3705 Conversion - English/Metric Page 7756 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 11732 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 6506 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Page 4078 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1279 Solar Sensor: Description and Operation SUNLOAD SENSOR The sunload sensor is a 2 wire photo diode. The vehicle uses left and right sunload sensors. The two sensors are integrated into the sunload sensor assembly. Low reference and signal circuits enable the sensor to operate. As the light shining upon the sensor gets brighter, the sensor resistance increases. The sensor signal decreases as the resistance increases. The sensor operates within an intensity range between completely dark and bright. The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between 0-255 counts. The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted sunload value. This value will not be displayed on the scan tool. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is fixed. The scan tool parameter for the sunload sensor is the actual state of the signal circuit. Page 15243 Fuel Gauge Sender: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 2503 4. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the fill plug threads. 5. Install the fill plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 6. Install the transfer case shield, if equipped. 7. Lower the vehicle. Refer to Vehicle Lifting. Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 15872 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Page 11317 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 15424 Various symbols are used in order to describe different service operations. Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test ^ Tools Required J 35667-A Cylinder Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the diagnosis. The cylinder leakage test may be used in conjunction with the engine compression test, to isolate the cause of leaking cylinders. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the battery ground (negative) cable. 2. Remove the spark plugs. 3. Install J 35667-A. 4. Measure each cylinder on the compression stroke, with the valves closed. Important: It may be necessary to hold the crankshaft balancer bolt, to prevent piston movement. 5. Apply air pressure, using J 35667-A. Refer to the manufacturer's instructions. 6. Record the cylinder leakage readings for each cylinder. Important: ^ Normal cylinder leakage is from 12 to 18 percent. ^ Make a note of any cylinder with more leakage than the other cylinders. ^ Any cylinder with 30 percent leakage or more requires service. 7. Inspect the four primary areas, to properly diagnose a leaking cylinder. 8. If air is heard from the intake or exhaust system, perform the following procedure: ^ Remove the camshaft cover. Ensure the valves are closed. - Inspect the cylinder head for a broken valve spring. ^ Remove the cylinder head and inspect. 9. If air is heard from the crankcase system at the crankcase (oil filler tube), perform the following procedure: ^ Remove the piston from the suspect cylinder. ^ Inspect the piston and connecting rod assembly. ^ Inspect the engine block. 10. If bubbles are found in the radiator, perform the following procedure: ^ Remove the cylinder head and inspect. ^ Inspect the engine block. 11. Remove the J 35667-A. 12. Install the spark plugs. 13. Install the battery ground (negative) cable. Page 4094 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 12229 Power Seat Track: Service and Repair Power REMOVAL PROCEDURE 1. Remove the front bucket seat assembly from the vehicle. 2. Remove the seat cushion trim panel. 3. Remove the seat belt buckle nut. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1, 4), and remove the SIR harness from the seat. Page 4882 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 8851 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12452 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 15711 Electrical Symbols Part 6 Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger REMOVAL PROCEDURE Page 8965 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. Page 1696 Electrical Symbols Part 3 Page 13111 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Page 11929 Circuit/System Testing Component Testing Page 11833 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 1593 Electrical Symbols Part 2 Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 10584 3. Install the accumulator clamp nut. Tighten Tighten the nut to 10 N.m (88 lb in). 4. Install the A/C low pressure switch. Tighten Tighten the A/C low pressure switch to 5 N.m (44 lb in). 5. Install new O-ring seals. 6. Install the accumulator to the evaporator. 7. Install the accumulator retaining nut. Tighten Tighten the nut to 28 N.m (21 lb ft). 8. Connect the compressor suction hose to the accumulator (4). 9. Install the suction hose nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 10. Connect the electrical connector to the A/C low pressure switch. 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 12. Leak test the fitting of the component using the J 39400. Page 7384 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-04-19-002B Date: 040404 Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Page 7475 Page 7383 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 9217 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 15168 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 2877 4. Install the camshaft caps and bolts. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 5. Remove the J 44221 6. Carefully move the sprockets back onto the camshafts and remove the J 44222. 7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 8. Install the camshaft cover. Page 4029 Various symbols are used in order to describe different service operations. A/T - Key Will Not Release From Ignition Lock Cylinder Automatic Transmission Shift Boot: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 13098 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Rear Door Upper REMOVAL PROCEDURE OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 5754 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Locations Locations View Page 9845 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 408 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 12311 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 3862 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 2006 Page 8955 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 8161 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 1314 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 41 Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 5466 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7960 For vehicles repaired under warranty, use the table. Disclaimer Page 9543 22. Remove the screws retaining the IP bezel to the IP and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the dash, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 27. With both of the green connectors and the first breakout of four wires in hand, insert the new wiring harness from under the IP up to the radio area of the IP, where the radio is normally positioned. 28. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 29. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 30. Disconnect the mechanics wire from the speaker wires, connect the speaker wires to the speaker and fasten the speaker to the IP. 31. Repeat the last three steps for the right speaker. 32. Remove the CPA from the radio connector, remove the wires shown below from the radio connector and replace them with the wires from the new wiring harness. ^ Remove wire in cavity B9 and insert the Brown wire. ^ Remove wire in cavity B8 and insert the Brown/White wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Blue wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminal from the wires you just removed from the connector. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet to the area of the rear audio control, and reposition the carpeting. 35. Remove the CPA from the rear audio control connector and remove four wires from the Rear Audio Control in-line harness connector and replace them with the wires from the new harness as listed below. ^ Remove wire in cavity B3 and insert the Brown wire. ^ Remove wire in cavity A8 and insert the Brown/White wire. ^ Remove wire in cavity A9 and insert the Blue wire. ^ Remove wire in cavity A1 and insert the Black wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires of the original harness, as close to the taped portion of the harness as possible. 36. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 37. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 38. Route the new harness under the carpet from the rear of the console to the 8-way connector. 39. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE Specifications Valve Guide Seal: Specifications Valve Stem Clearance - Intake 0.0011-0.0025 inch Valve Stem Clearance - Exhaust 0.0015-0.0030 inch Electrical - No Start/Multiple Systems Inoperative Audible Warning Device: Customer Interest Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Page 4074 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 59 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1675 Page 677 For vehicles repaired under warranty, use the table. Disclaimer Page 4980 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 15929 6. If replacing the reading lamp bulb (1), remove the reflector (2) from the dome lamp. 7. Remove the reading lamp bulb from the socket. 8. If replacing the dome lamp bulb (1), remove the dome lamp bulb from the socket. INSTALLATION PROCEDURE Page 4874 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Locations Locations View Page 1456 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13690 Electrical Symbols Part 4 Page 4244 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3878 Powertrain Control Module (PCM) C2 Part 2 Page 14632 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Specifications Brake Pad: Specifications Pad minimum thickness See Note Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Description and Operation Power Door Lock Switch: Description and Operation The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Page 10059 5. Install the power steering cooler hose (2) to the power steering pump. 6. Install the power steering pressure hose (1) to the power steering pump. Tighten the power steering pressure hose to 25 Nm (18 ft. lbs.). 7. Remove the drain pan from under the vehicle. 8. Install the drive belt. 9. Install the air cleaner assembly. 10. Install the radiator air intake baffle. 11. Bleed the power steering system. 12. Inspect the power steering system for leaks and the hoses for clearance away from the frame and other components. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 15511 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10298 Lateral Stabilizer Rod: Service and Repair Rear Axle Tie Rod Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Raise and support the rear axle at the designed D - height. Important: When disconnecting the rear axle tie rod, the air suspension system must be Repressurized or the body my shift during the repair. 3. If equipped with air suspension, Repressurize the air suspension system. 4. Remove the rear axle tie rod to the axle mounting bolt and nut. 5. Remove the rear axle tie rod to frame mounting bolt and nut. 6. Remove the rear axle tie rod from the vehicle. Installation Procedure Important: When installing the rear axle tie rod the bushings inner sleeve off set (largest gap) is towards the rear axle. Page 15139 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1221 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Left REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 14286 Seat Adjuster Switch - Driver (W/O Memory Seat) Page 4426 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5982 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8988 Page 9890 For vehicles repaired under warranty use the table shown. DISCLAIMER Bose(R) Premium Sound With Rear Audio Controls These vehicles use wiring harness P/N 15164931. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconned the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). Page 10731 Electrical Symbols Part 7 Page 10315 Stabilizer Bushing: Service and Repair Rear Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator clamp mounting nut. 3. Remove the stabilizer shaft insulator clamp. 4. Remove the stabilizer shaft insulator from the stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft insulator to the stabilizer shaft. 2. Install the stabilizer shaft insulator clamp. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft insulator clamp mounting nut. Tighten the stabilizer shaft insulator clamp mounting nut to 70 Nm (52 ft. lbs.). 4. Lower the vehicle. Page 14545 Sunroof Switch Page 7852 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5873 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 11735 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 4139 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4234 Electrical Symbols Part 3 Page 15186 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 8850 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3802 Body Control Module: Description and Operation The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the Driver Door Module (DDM), Passenger Door Module (PDM) and the Liftgate Module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Diagrams Fuel Pump And Sender Assembly Page 9891 22. Remove the screws retaining the IP bezel to the IP and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the dash, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 27. With both of the green connectors and the first breakout of four wires in hand, insert the new wiring harness from under the IP up to the radio area of the IP, where the radio is normally positioned. 28. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 29. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 30. Disconnect the mechanics wire from the speaker wires, connect the speaker wires to the speaker and fasten the speaker to the IP. 31. Repeat the last three steps for the right speaker. 32. Remove the CPA from the radio connector, remove the wires shown below from the radio connector and replace them with the wires from the new wiring harness. ^ Remove wire in cavity B9 and insert the Brown wire. ^ Remove wire in cavity B8 and insert the Brown/White wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Blue wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminal from the wires you just removed from the connector. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet to the area of the rear audio control, and reposition the carpeting. 35. Remove the CPA from the rear audio control connector and remove four wires from the Rear Audio Control in-line harness connector and replace them with the wires from the new harness as listed below. ^ Remove wire in cavity B3 and insert the Brown wire. ^ Remove wire in cavity A8 and insert the Brown/White wire. ^ Remove wire in cavity A9 and insert the Blue wire. ^ Remove wire in cavity A1 and insert the Black wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires of the original harness, as close to the taped portion of the harness as possible. 36. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 37. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 38. Route the new harness under the carpet from the rear of the console to the 8-way connector. 39. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE Page 5496 Fuel Injector Balance Test With Special Tool - Steps 6-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the Injector Balance Test Example. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics Page 10545 Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 1. Install the wheel and the tire assembly. Align the locating mark of the tire and wheel to the hub assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel nuts hand tight. Tighten the nuts evenly and alternately to avoid excessive runout. Tighten the wheel nuts to 140 Nm (103 ft. lbs.) using J39544-KIT./ 3. Install the wheel hub cap, if equipped. 4. Lower the vehicle. Page 7998 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 12962 4. Install the front door sill plate. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 72 Disclaimer Page 2129 For vehicles repaired under warranty, use the table. Disclaimer Page 14525 Seat Adjuster Switch - Front Passenger (W/Memory Seat) Audio/A/C - Settings Change While Driving Body Control Module: All Technical Service Bulletins Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6102 Electrical Symbols Part 6 Page 6118 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 13203 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws (2) that retain the lock actuator (1) to the latch assembly. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the latch assembly to the liftgate. Page 4871 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 4413 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 9124 Page 12868 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 11278 28. Twist together one connector wire lead to one deployment wire. 29. Inspect that the previous connection is secure. 30. Bend flat the twisted connection. 31. Secure and insulate the connection using electrical tape. 32. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 9958 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 11910 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 9467 C307 Part 2 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 3612 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 7639 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 15644 2. Mask off the desired amount of material to be removed. 3. Open the liftgate glass. Note: Do no damage the applique or the liftgate glass when removing the applique from the liftgate glass. 4. Remove the screws that retain the applique to the liftgate glass. 5. With a flat-bladed tool, carefully remove the applique from the liftgate glass. 6. Remove the CHMSL harness grommet from the roof panel. 7. Disconnect the CHMSL harness connector and remove CHMSL applique from the vehicle. 8. Using a 1/4" die grinder and Scotch-Brite(R) Disc, 3M(R) P/N 07481, remove excess material from the applique. 9. Paint the applique to match. Important: If the original part is used, it is important to seal (clear coat) the edge to protect the clear coat from lifting. 10. Remove the old adhesive from the underside of the applique. 11. Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 12. Apply double-sided adhesive tape, 3M(R) P/N 06397, or equivalent, to the underside of the CHMSL applique. 13. Remove the old adhesive from the liftgate glass. Important: ^ The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. ^ DO NOT use commercial glass or surface cleaners. These may contain petroleum. ^ The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). 14. Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 15. Apply adhesive promoter, P/N 12378555, in Canada, use P/N 88901239, to the liftgate glass surface, completely wetting the applique application Page 1513 Electrical Symbols Part 4 Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Body - Door(s) Are Difficult To Close Front Door Striker: All Technical Service Bulletins Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 6738 Page 8390 3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic. 4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3). 5. Install the washer and snap ring retaining the motor/encoder rotary position sensor. 6. Install the motor/encoder gasket (1). Page 8297 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3114 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3). 2. Remove the oil level indicator and tube. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove left and right front tire and wheel assemblies. 5. Remove the engine protection shield mounting bolts. 6. Remove the engine protection shield. 7. Remove the steering gear crossmember, front. 8. Remove the left and right wheel drive shaft. 9. Remove the front drive axle clutch fork assembly. Page 3618 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 6042 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4102 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: Customer Interest Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 10229 Ball Joint: Service and Repair Upper Ball Joint Upper Ball Joint Replacement Tools Required ^ J9519-E Lower Ball Joint Remover and Installer ^ J21474-01 Control Arm Bushing Set ^ J45117Ball Joint Installation Spacer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the steering knuckle with wheel hub attached. 4. Remove the upper ball joint retaining clip. 5. Remove the upper ball joint boot. 6. Remove the upper ball joint from the steering knuckle using J9519-E. Installation Procedure Page 8334 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 12435 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 3951 Electrical Symbols Part 8 Page 14363 IMPORTANT: Ensure that the hook and loop retaining strips remain attached to the seat back pad. 12. Release the cover from the hook and loop retaining strips on the front of the seat back pad. 13. Remove the 6 push-pins from the seat back. 14. Remove the cover and pad from the seat back. Page 1179 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Page 3704 Various symbols are used in order to describe different service operations. Page 13818 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 935 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 10415 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). Page 125 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 5322 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 4513 Intake Air Temperature (IAT) Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 13317 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4760 Scan Tool Does Not Communicate With Class 2 Device - Steps 16-20 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 4. The following DTCs may be retrieved with a history status. These DTCs are not the cause of the present condition. - U1300 - U1301 - U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 with a current status. This indicates that the malfunction occurred when the ignition was on. 10. Normal class 2 serial data communication cannot take place until the body control module (BCM) sends the appropriate power mode message. If the BCM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 12. Normal class 2 serial data communication cannot take place until the body control module (BCM) sends the appropriate power mode message. If the BCM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 17. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 18. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Common signal ground at terminal 5. The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Page 14070 Liftgate Module (LGM) C2 (Except XUV) Page 14923 Electrical Symbols Part 5 Page 12241 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 4047 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 2727 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4169 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. Page 14288 Seat Adjuster Switch - Passenger (W/O Memory Seat) Page 479 Liftgate Module (LGM) C2 (Except XUV) Page 1039 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 5769 Electrical Symbols Part 3 Page 9306 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 1616 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9484 C304 Part 2 C305 Page 13114 4. Attach the molding to the outside of the door with double sided tape. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip. 9. Install the inner window belt sealing strip. 10. Install the trim panel. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. INSTALLATION PROCEDURE Page 986 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 1081 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 2399 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 14757 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4135 Electrical Symbols Part 6 Page 5808 Electrical Symbols Part 1 Page 11588 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 15456 Volt Meter Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15121 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 14629 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Locations Fuel Pump Relay: Locations FUEL PUMP RELAY Locations View Page 14372 9. Install the inboard rear seat back hinge cover with three screws. Tighten Tighten the rear seat back hinge cover screws to 2 N.m (18 lb in). 10. Install the seat belt bezel to the rear seal back with the plastic retainers (2) 11. Install the head restraint assembly. Engine Mount and Bracket Replacement- Left Engine Mount: Service and Repair Engine Mount and Bracket Replacement- Left Engine Mount and Bracket Replacement- Left ^ Tools Required J 41240 Fan Clutch Remover and Installer Removal Procedure 1. Disconnect the negative battery cable. 2. Using the J 41240 to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft. 3. Remove the MAP sensor electrical connector and the retainer (1). 4. Remove the MAP sensor (2). 5. Remove the left shock module (if frame mount is being removed). Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 1971 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 44218 Seal Installer Removal Procedure Important: Do not damage the engine front cover or the crankshaft. 1. Remove the crankshaft balancer. 2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal. Installation Procedure 1. Apply the engine oil to the outside diameter of the crankshaft front oil seal. Page 16002 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Lumbar Adjuster Switch - Driver (W/Memory Seat) Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Page 1610 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Specifications Shifter A/T: Specifications Floor shift Control Bolt ......................................................................................................................... ................................................ 10 Nm (89 inch lbs.) Page 7800 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Page 1766 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 6675 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 3947 Electrical Symbols Part 4 Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 13387 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Panel (Trailblazer EXT, Envoy XL) Molding Replacement - Rear Panel (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the tail lamp assembly from the vehicle. 2. Release the 4 tabs that retain the trim to the tail lamp. 3. Remove the trim from the tail lamp. Installation Procedure 1. Install the trim to the tail lamp, ensuring that the retaining tabs are fully seated. 2. Install the tail lamp assembly to the vehicle. Page 10130 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Locations Locations View Drivetrain - New Transfer Case Output Bearing Tool Output Shaft: Technical Service Bulletins Drivetrain - New Transfer Case Output Bearing Tool File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-007 Date: September, 2002 INFORMATION Subject: Release of New Tool J 45380 - Rear Output Shaft Bushing Remover and Installer Models: 1998-2003 Light Duty Truck Models with AWD or 4WD and any of the following Transfer Case Models: 126, 136, 149, 226, 233, 236, 246, 261 or 263 (Except 261 SHD or 263 SHD) A new tool, J 45380, has been released to remove and install the rear output shaft bearing. The following procedures may be used. Identification Identify the transfer case model as shown in the figure shown. Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information. 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Remove the rear output shaft seal. 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing using the J 45380. 6.1. Install the finger section of the J 45380 in the front of the bushing. Page 12593 1. Position the VCIM bracket to the seat bracket. 2. Slide the VCIM bracket forward until the retaining tabs become locked to the seat bracket. 3. Ensure the retaining tab (1) on the VCIM bracket is properly seated. 4. Install the communication interface module. 5. Position the right second row seat to a passenger position. Page 15791 Various symbols are used in order to describe different service operations. Page 1429 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 8901 9. Remove the rear brake pads. 10. Remove the brake pad retaining clips from the brake caliper mounting bracket. 11. Remove the retaining clip from the brake caliper. 12. Clean the brake caliper mounting bracket with denatured alcohol. 13. Using non-lubricated, filtered air, dry the brake caliper mounting bracket. Installation Procedure Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips. Page 10308 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 4626 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Door Handle Replacement - Rear Outside (TrailBlazer EXT, Envoy XL) Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside (TrailBlazer EXT, Envoy XL) Door Handle Replacement - Rear Outside (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip (1) retaining the lock rod (2) to the outside door handle. 4. Remove the lock rod (2) from the outside door handle. 5. Remove the nuts retaining the outside door handle to the door. 6. Remove the outside door handle from the door. Installation Procedure 1. Install the outside door handle to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the outside door handle to the door. Tighten the nuts to 10 N.m (89 lb in). 3. Install the lock rod (2) to the outside door handle. 4. Install the clip (1) retaining the lock rod (2) to the outside door handle. 5. Install the water deflector. 6. Install the door trim panel. Page 4240 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 14686 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. Page 15520 Equivalents - Decimal And Metric Part 2 Arrows and Symbols A/T - Water Or Coolant Contamination Information Transmission Cooler: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 10667 4. Remove the recirculation actuator screws. 5. Remove the electrical connector from the recirculation actuator. 6. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the recirculation actuator. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 3. Install the air inlet assembly. 4. Install the air inlet assembly screws. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 5. Connect the electrical connector to the recirculation actuator. 6. Install the HVAC module assembly. Page 10159 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 7206 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 489 Sunroof / Moonroof Module: Diagrams Sunroof Module Connector C1 Sunroof Module Connector C2 Page 1530 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 7727 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 9938 3. Measure the D height by measuring the distance between the jounce bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension is the average of the highest and lowest measurements. Cross vehicle D heights should be within 12 mm (0.5 inch) for vehicles equipped with coil springs, vehicles equipped with air suspension should be within 8 mm (0.3 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear suspension. ^ Collision damage. Page 2985 7. Remove the camshafts. Important: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations. 8. Remove the valve rocker arms. 9. Remove the valve lash adjusters. Installation Procedure Page 3997 Electrical Symbols Part 1 Page 11803 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 15685 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 9142 Page 1805 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3691 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15087 Malfunction Indicator Lamp (MIL) Inoperative - Steps 8-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Page 13957 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 7551 For vehicles repaired under warranty, use the table. Disclaimer Page 4658 Electronic Throttle Actuator: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) OVERVIEW The Throttle Actuator Control (TAC) system uses vehicle electronics and components to calculate and control the position of the throttle blade. This eliminates the need for a mechanical cable attachment from the accelerator pedal to the throttle body. This system also performs the cruise control functions as well. The TAC system components include, but are not limited to the following: The Accelerator Pedal Position (APP) sensors - The throttle body - The Powertrain Control Module (PCM) Each of these components interface together to ensure accurate calculations and control of the Throttle Position (TP). Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Throttle Body Assembly The throttle body for the TAC system is similar to a conventional throttle body with several exceptions. One exception being the use of a motor to control the throttle position instead of a mechanical cable. Another exception is the throttle position (TP) sensor. The TP sensor is mounted in the throttle body assembly. The TP sensor is 2 individual TP sensors within the throttle body assembly. Two separate signal, low reference, and 5-volt reference circuits are used to connect the TP sensors and the PCM. TP sensor 2 signal voltage increases as the throttle opens. TP sensor 1 signal voltage decreases as the throttle opens. MODES OF OPERATION Battery Saver Mode If the Powertrain Control Module (PCM) detects the ignition ON for 10 seconds without the engine running, the PCM will allow the throttle blade to return to the default position. This removes the draw that is present while holding the throttle blade at the calculated idle position. Reduced Engine Power Mode When the PCM detects a problem with the TAC system the PCM enters one of the following Reduced Engine Power Modes: Acceleration Limiting-The control module will continue to use the accelerator pedal for throttle control, however the vehicle acceleration is limited. - Limited Throttle Mode-The control module will continue to use the accelerator pedal for throttle control, however the maximum throttle opening is limited. - Throttle Default Mode-The control module will turn off the throttle actuator. - Forced Idle Mode-The control module will perform the following actions: Limit engine speed to idle by positioning throttle position, or by controlling fuel and spark if throttle is turned off. - Ignore accelerator pedal input. - Engine Shutdown Mode-The control module will disable fuel and de-energize the throttle actuator. Page 7995 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 16029 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 7597 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 5950 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 3129 Electrical Symbols Part 8 Page 13702 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 10747 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 13997 Disclaimer Page 5959 Various symbols are used in order to describe different service operations. Page 7845 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2278 3. Measure the D height by measuring the distance between the jounce bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension is the average of the highest and lowest measurements. Cross vehicle D heights should be within 12 mm (0.5 inch) for vehicles equipped with coil springs, vehicles equipped with air suspension should be within 8 mm (0.3 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear suspension. ^ Collision damage. Page 9822 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O-ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 261 Page 2681 The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: Beneath the lower control arms, inboard from the shock absorber mounts. - Beneath the center of the front crossmember. The rear end lift points for the floor jack are at the following locations: Beneath the axle housing, inboard from the shock absorber mounts. - Beneath the axle differential. Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: Chock the wheels at the end of the vehicle opposite the end being lifted. - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame. - Beneath the front suspension crossmember. - Beneath the axle. When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter. - The brake lines. - The brake cables. - The fuel filter. - The accelerator cables. - The transmission shift cables. Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 233 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 1237 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Recline the driver seat rearward to access the left center trim pillar. 1. Remove the upper portion of the left center trim pillar. 2. Disconnect the electrical connector. 3. Remove the retaining clips from the B pillar. 4. Remove the inside air temperature sensor assembly (1) from the B pillar. INSTALLATION PROCEDURE 1. Connect the electrical connector to the inside air temperature sensor assembly (1). 2. Install the inside air temperature sensor assembly (1) to the B pillar. 3. Install the retaining clips to the B pillar. 4. Install the upper portion of the left center trim pillar. Page 14432 2. Remove the 2 bolts securing the bracket assembly to the seat cushion. 3. Remove the bracket assembly from the seat cushion. Installation Procedure 1. Position the bracket assembly on the seat cushion. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts securing the bracket assembly to the seat cushion. Tighten the rear seat cushion bracket bolts to 25 N.m (18 lb ft). 3. Install the rear seat cushion assembly in the vehicle. Seat Cushion Bracket Replacement - Rear No. 1 (TrailBlazer EXT, Envoy XL) Seat Cushion Bracket Replacement - Rear No. 1 (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the seat from the vehicle. Page 10695 Air Register: Service and Repair Air Outlet Replacement - Rear Floor REMOVAL PROCEDURE 1. Remove the console support bracket. 2. Remove the push pin (1). 3. Rotate the air outlet duct-rear (3) to remove from the console support bracket (1). 4. Remove the air outlet duct-rear from the vehicle. INSTALLATION PROCEDURE Page 7077 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 12436 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 13566 40. Pull the communication interface module electrical connectors back through the hole in the carpet. 41. Remove the cellular antenna coax cable from the inner coupling on the left body side window. 42. Remove the coat hooks from the roof panel. 43. Disconnect the antenna module electrical connector from the right and left body side windows. 44. Disconnect the electrical connector from the right-hand body side window actuator. 45. Disconnect the electrical connector from the left-hand body side window actuator. 46. Remove the windshield rearview mirror wire harness cover. 47. Disconnect the inside rear view mirror electrical connector (3). 48. Disconnect the rain sensor electrical connector (2), if equipped. 49. Disconnect the coax cable (1) from the navigational antenna, if equipped. Page 15904 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12243 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 4152 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 39 Page 11244 Impact Sensor: Description and Operation Inflatable Restraint Sensing and Diagnostic Module INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 8862 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Locations Locations View Page 4036 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Page 7225 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14700 Trunk / Liftgate Weatherstrip: Service and Repair Lift Gate REMOVAL PROCEDURE 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. INSTALLATION PROCEDURE 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Page 13978 Driver Door Module (DDM) C3 Page 461 For vehicles repaired under warranty, use the table. Disclaimer Page 5870 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15003 Fuel Gauge Sender: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 4189 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 14524 Seat Adjuster Switch - Driver (W/O Memory Seat) Page 15013 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 6114 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 10135 Radio/Audio System Schematics: Steering Wheel Controls Page 4165 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Drivetrain - Front Drive Axle Squeal/Squeak Seals and Gaskets: All Technical Service Bulletins Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Page 7737 Page 4463 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Page 2918 Important: Once this procedure is done, it is not necessary to reset the trim tool assembly EN 45680-411 height until the blades are worn or damaged. 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 N.m (14 lb ft). 10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block. 11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 N.m (15 lb ft). 12. Fasten drive adapter EN 45680-866 (1) into the drill chuck. 13. Connect a compressed air supply 517-862 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411. 16. Turn off the compressed air valve (2). Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 9910 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 9191 3. Install the bolt that secures the harness to the engine block. Tighten Tighten the bolt to 50 N.m (37 lb ft). 4. Install the bolt that secures the harness to the wheelhouse panel (1). Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Connect the negative battery cable to the battery. Page 5962 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 5327 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12439 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 2218 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1018 16. Inspect the inside of the electrical connector on the wiper motor for moisture or water. If no moisture or water is found, continue inspecting for evidence or signs that moisture or water was present at some earlier time. Indicators include water stains, dried dirt, etc. (1). ^ If moisture or water is found in the electrical connector, or if there is evidence that there was moisture or water present at an earlier time, the complete wiper motor module (including the motor) MUST be replaced. Obtain a new wiper module and proceed to Step 20. The new wiper modules already have a different style of breathable seal on the wiper cover. DO NOT install the breathable seal described later in this recall on new wiper modules. ^ If there is no moisture or water found in electrical connector, or if there is NO evidence that moisture or water was present at an earlier time, a breathable seal must be installed over the vent in the wiper motor cover. Proceed to the next step. 17. Clean the exterior surface of the wiper motor cover thoroughly (1). It must be free of dirt, grease, oil, and other contamination. Important To ensure good adhesion of the seal being installed in the next steps, make sure that your hands are clean and free of oil and grease before proceeding. 18. Using the alcohol wipe included in the kit, wipe the complete exterior surface of the wiper cover thoroughly. Allow the surface to dry approximately 30-45 seconds before proceeding. Important When using the adhesion promoter in the next step: ^ DO NOT open the adhesion promoter until you are ready to apply it. ^ Use the complete contents of the packet as soon as it is opened. ^ If the packet is dried-out when opened, obtain another sealer kit or use P/N 12378462 (4 oz. can of adhesion promoter). ^ Do not allow the liquid to "spill" inside of the vent opening on the wiper motor cover when applying. ^ Allow to dry 30-90 seconds before applying the seal. 19. Carefully apply the adhesion promoter that is included in the kit. Important The seal must be inspected before installing. If there are any creases in the seal or backing material, the seal must NOT be used. Obtain another sealer kit. ^ If you are unable to remove the backing material from the seal in the next step, the seal is beyond its shelf life of one year. Obtain another sealer kit. Do NOT touch the adhesive surface on the seal when removing the backing material. Page 3888 control module damage may occur. - If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. AFTER PROGRAMMING A CONTROL MODULE The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: Fuel trim correction - Idle Air Control (IAC) learned position - Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: The crankshaft variation learn procedure - The engine oil life reset procedure - The idle learn procedure - The inspection/maintenance complete system set procedure - The vehicle theft deterrent password learn procedure - The Throttle Position (TP) sensor learn procedure Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 13135 Important: In any area damaged beyond recognition, space the plug weld holes every 40 mm (1 1/2 in) apart. 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all of the attachment surfaces as necessary. 3. Position the hinge bracket 4. Plug weld accordingly. 5. Clean and prepare all of the welded surfaces. Important: Prior to refinishing, refer to publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendation. 6. Apply the following as necessary: Page 4160 Equivalents - Decimal And Metric Part 1 Specifications Fan Shroud: Specifications Fan Shroud Bolts 1.5 ft. lbs. Page 11945 Page 3228 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12055 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 2516 Engine Oil: Description and Operation Api Oil and Additives WHAT KIND OF ENGINE OIL TO USE Oils recommended for your vehicle can be identified by looking for the starburst symbol. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Do not use any oil which does not carry this starburst symbol. If you choose to perform the engine oil change service yourself, be sure the oil you use has the starburst symbol on the front of the oil container. If you have your oil changed for you, be sure the oil put into your engine is American Petroleum Institute certified for gasoline engines. You should also use the proper viscosity oil for your vehicle, as shown in the viscosity chart. As in the chart shown previously, SAE 5W-30 is the only viscosity grade recommended for your vehicle. You should look for and use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If you cannot find such SAE 5W-30 oils, you can use an SAE 10W-30 oil which has the API Starburst symbol, if it's going to be 0°F (-18°C) or above. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. NOTICE: Use only engine oil with the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Don't add anything to your oil. The recommended oils with the starburst symbol are all you will need for good performance and engine protection. Page 1861 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4802 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 4627 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12314 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 2789 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 12040 Electrical Symbols Part 1 Page 1247 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 5106 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3243 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3623 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 3879 Powertrain Control Module (PCM) C3 Page 14179 1. Position the head restraint retractor assembly to the seat back. 2. Install the release cable through the head restraint retractor assembly access hole and sliding the cable retainer into position. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 3 bolts that retain the head restraint retractor assembly to the seat back frame. Tighten Tighten the head restraint retractor bolts to 10 N.m (88 lb in). 4. Install the seat back cover and pad. Head Restraint Guide Assembly Replacement - Rear No. 2 REMOVAL PROCEDURE Page 7869 1. Install the new seal on the transfer case adapter. 2. Install the transfer adapter to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter mounting bolts to the transmission. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 4. Lower the transmission to install the transmission mount bolts. 5. Install the transmission mount bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the transmission jack. 7. Install the transfer case assembly to the vehicle. 8. Lower the vehicle. Refer to Vehicle Lifting. Page 10269 5. Disconnect the ABS wheel speed sensor wiring harness from the upper control arm. 6. Remove the upper control arm mounting bolts. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper control arm mounting bolts. Tighten the upper control arm mounting bolts to 150 Nm (111 ft. lbs.). Page 15495 Electrical Symbols Part 7 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 491 Tighten the sunroof module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the module. 4. Install the drive motor to the sunroof assembly. 5. With the aid of an assistant, install the sunroof assembly to the vehicle. Refer to Sunroof Replacement. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Page 5626 On some 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles currently or previously registered in the corrosion areas shown above, the fuel tank modular reservoir assembly, which contains the fuel pump, may develop corrosion of the fuel feed/return pipes after an extended period of time. Severe corrosion may cause the formation of small perforations. These perforations may allow a small amount of fuel to accumulate in a recessed area outside of the fuel tank. If this were to occur, it would be accompanied by a fuel odor. If left uncorrected and the corrosion is allowed to progress, a fuel spray from the pipes may begin to occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to replace the fuel tank modular reservoir. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 30, 2008, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 30, 2008, must be submitted to the Service Contract provider. Vehicles Involved Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 10701 Locations View - HVAC Systems - Automatic Page 13632 Tighten the rear upper quarter trim panel screw to 2 N.m (18 lb in). 5. Install the cargo net retaining knobs. Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the cargo shade/cover. 2. Remove the left body side upper trim panel. 3. Remove the liftgate sill plate. 4. Remove the left rear door sill panel. 5. Remove the lower seat belt anchor bolt. 6. Release the clips that retain the trim panel to the body. 7. Remove the trim panel from the vehicle. INSTALLATION PROCEDURE 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Seat the clips the retain the trim panel to the body. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the seat belt lower anchor. Tighten Page 5567 Electrical Symbols Part 1 Page 15975 Electrical Symbols Part 3 Page 2007 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 512 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 1709 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5596 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9043 Parking Brake Cable: Service and Repair Disabling the Park Brake Cable Automatic Adjuster Disabling the Park Brake Cable Automatic Adjuster 1. Place the park brake lever in the full release position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Handling the parking brake cables during service requires extra care. Damage to the nylon coating reduces the corrosion protection. If the damage area passes through the nylon coating, increased parking brake effort could result. Avoid contacting the protective coating with sharp-edge tools or the sharp surfaces of the vehicle underbody. 3. Pull the park brake cable equalizer toward the rear of the vehicle and place a locking plier with protected jaws on the cable to hold the cable in an extended position. 4. Lower the vehicle. 5. Rotate the self-adjust clip into the lock position with a flat bladed tool. 6. Raise the vehicle. 7. Remove the locking plier from the park brake cable. 8. Lower the vehicle. 9. Partially raise the park brake lever, stopping prior to the self-adjust clip activating on the mount bracket tab. 10. Insert a flat bladed tool behind the self-adjust clip and twist the tool 90° to raise the self-adjust clip over the mount bracket tab. 11. Raise the handle until it is fully applied and remove the screwdriver. Page 359 Disclaimer Page 13651 Door Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector from the door. 3. Remove the outside handle from the door. 4. Remove the lock cylinder from the door handle. Installation Procedure 1. Install the lock cylinder to the door handle. 2. Install the outside handle to the door. 3. Install the water deflector to the door. 4. Install the door trim panel to the door. Page 2211 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Procedures Seat Cushion: Procedures Seat Cushion Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the rear seat bracket trim cover. 2. Remove the hydraulic jack from the jack stowage area, on the left side only. 3. Position the seat cushion assembly in order to gain access to the 2 rear seat mounting nuts. 4. Remove the 2 mounting nuts. 5. Remove the seat cushion assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the seat cushion assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 nuts that retain the seat cushion assembly to the floor panel. Tighten Tighten the rear seat mounting nuts to 45 N.m (33 lb ft). 3. Install the hydraulic jack into the jack stowage area, on the left side only. 4. Adjust the seat cushion assembly to the latched position. 5. Install the rear mount trim cover. Trailblazer, Envoy, and Bravada Page 237 Page 13095 Rear Door Weatherstrip: Service and Repair Rear Door Upper REMOVAL PROCEDURE 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. INSTALLATION PROCEDURE 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Page 12857 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 4277 Electrical Symbols Part 5 Locations Page 6987 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). Page 4885 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 9853 WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 40. Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. 41. Reposition the rear electrical center through the carpet and reposition the carpet. 42. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 43. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 44. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 45. Turn the key OFF. Remove the key. 46. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 47. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 48. Reinstall the rear electrical center cover. 49. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 50. Reinstall the knee bolster (TrailBlazer). 51. Reinstall the closeout/insulator panel (TrailBlazer). 52. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 53. Reinstall the console to the vehicle and install the retainers. 54. Reinstall the shift boot and handle assembly. 55. Reinstall the console bin and retainers. 56. Reinstall the first lock pillar trim and carpet retainers to both door openings. 57. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). Page 928 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3686 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Locations Locations View Page 11967 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 9498 C900 C901 Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling-Colder plug ^ Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 14668 Rear Door Weatherstrip: Service and Repair Auxiliary REMOVAL PROCEDURE 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 4651 Location Views Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Locations Locations View Page 14642 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers (2) to the front door sealing weatherstrip located at the base of the pillar. 4. Close the door. Page 8461 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 1193 DISCLAIMER Page 1324 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1795 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 13526 Console: Service and Repair Console Storage Bin Replacement Console Storage Bin Replacement Removal Procedure 1. Open the storage bin cover. 2. Remove the 6 screws that retain the storage bin to the console. 3. Remove the storage bin from the console. Installation Procedure 1. Install the storage bin to the console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 6 screws that retain the storage bin to the console. Tighten the screws to 2.5 N.m (22 lb in). 3. Close the storage bin cover. Page 4421 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 6113 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11679 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 12631 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 12949 For 2007 vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Page 3552 Heater Control Valve: Service and Repair COOLANT BYPASS VALVE REPLACEMENT TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181, disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose toward in order to disengage the hose from the heater core. 4. Position the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the vacuum hose from the coolant bypass valve. 8. Remove the coolant bypass valve. 9. Position the clamps at the coolant bypass valve. 10. Remove the heater inlet hoses form the coolant bypass valve. INSTALLATION PROCEDURE Page 7315 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 11403 2. Install the center seat belt anchor bolt that retains the center seat belt anchor to the seat belt buckle/anchor plate assembly. Tighten the bolt finger tight. 3. Position the seat belt buckle/anchor plate assembly to the rear seat back hinge bracket. 4. Install the left rear seat back rear mounting nut that retains the left seat back to the floor panel. Tighten ^ Tighten the rear seat back rear mounting nut to 45 N.m (33 lb ft). ^ Tighten the center seat belt anchor bolt to 50 N.m (37 lb ft). 5. Return the rear seats to the passenger position. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the 3 screws securing the inboard rear seat back hinge cover. 2. Remove the seat belt side buckle nut (2). 3. Remove the seat belt side buckle (1) from the seat. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 4354 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 13195 Liftgate Module (LGM) C3 (Except XUV) Page 4462 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 1532 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 9037 6. Install a pole jack with a block of wood under the fuel tank. 7. Remove the shield for the fuel tank. 8. Remove the rear support bracket from the fuel tank. Important: When performing this service procedure, the fuel tank will only drop about four inches when supported by the pole jack. It is not necessary to lower the fuel tank any further than that. 9. Lower the fuel tank to allow access to the rear park brake cable retainer above the fuel tank. 10. Remove the park brake cable retaining nuts from the underbody mounting studs. 11. Remove the park brake cable from the park brake cable retainers, left rear shown. Page 2437 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor discharge hose nut. Tighten Tighten the hose nut to 28 N.m (21 lb ft). 4. Install the compressor suction hose to the stud on the engine. 5. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor suction hose to the engine lift bracket. 7. Install the bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). 8. Connect the compressor suction hose (1) to the accumulator. 9. Install the compressor suction hose nut to the accumulator. Page 14892 DISCLAIMER Page 10069 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Front Stabilizer Bushing: Service and Repair Front Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise the and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator clamp mounting bolts. 3. Remove the stabilizer shaft insulator clamp from the stabilizer shaft insulator. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulator. Installation Procedure 1. Install the stabilizer shaft insulator to stabilizer shaft with slit facing the front of the vehicle. 2. Install the stabilizer shaft insulator clamp to the stabilizer shaft insulator. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft insulator clamp mounting bolts. Tighten the stabilizer shaft insulator clamp mounting bolts to 55 Nm (41 ft. lbs.). 4. Lower the vehicle. A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 4037 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 156 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 4187 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 1028 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Page 8391 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 7. Install the motor/encoder to the transfer case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 8. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 9. Connect the motor/encoder electrical connector (1). 10. Install the fuel tank shield, if equipped. 11. Lower the vehicle. Page 3153 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling-Colder plug ^ Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 11079 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 11563 Antenna, Navigation: Description and Operation CELLULAR AND NAVIGATION ANTENNAS The cellular antenna is the component that allows the OnStar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the Vehicle Communication Interface Module. The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a "low noise" amplifier that allows for a more broad and precise reception of this data. Current GPS location is collected by the module every time a keypress is made. The OnStar(R) Call Center also has the capability of "pinging" the vehicle during an OnStar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as "aged". In the event the VCP loses or is removed from power, this history location is used by the OnStar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Page 5676 Electrical Symbols Part 6 Page 2230 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door REMOVAL PROCEDURE 1. Using a flat-bladed tool, remove the window switch bezel from the door trim panel. 2. Disconnect the electrical connector from the window switch. 3. Release the retaining clips that attach the power window switch to the bezel. 4. Remove the switch from the bezel. INSTALLATION PROCEDURE 1. Install the switch to the bezel. Ensure that the retainers are fully seated. 2. Connect the electrical connector to the window switch. 3. Install the window switch bezel to the door trim panel. 4. Ensure that the window switch bezel retaining clips are fully seated. Page 4409 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 7309 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 14419 REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the 2 bolts securing the bracket assembly to the seat cushion. 3. Remove the bracket assembly from the seat cushion. INSTALLATION PROCEDURE Page 757 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 13945 Electrical Symbols Part 4 Page 3000 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 38820 Valve Stem Seal Remover and Installer - J 44222 Camshaft Sprocket Holding Tool - J 44228 Valve Spring Compressor Removal Procedure Important: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components, as previously installed. 1. Remove the cam cover. 2. Remove the spark plugs. 3. Remove the exhaust and the intake sprocket bolts. 4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components. 5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension. 6. Carefully move the sprockets with the timing chain, off of the camshafts. 7. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 8. Remove the camshaft caps. OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 6116 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 9691 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 5224 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Locations Locations View Page 154 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 13740 1. Install the battery with the positive (+) side down. Use one 3 volt, type CR2032 battery, or the equivalent. 2. Ensure that the seal is in position. 3. Align the two halves of the case together and squeeze the case closed until the tabs are fully seated. Page 11849 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 4692 Electrical Symbols Part 4 Page 2329 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13555 For vehicles repaired under warranty, use the table. Disclaimer Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 3769 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 12768 Disclaimer Page 5316 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10136 Steering Mounted Controls Transmitter: Description and Operation STEERING WHEEL CONTROLS The steering wheel controls for the HVAC system include air temperature and blower motor speed adjustments. Pressing the up arrow on the air temperature switch increases the outlet air temperature. Pressing the down arrow on the air temperature switch decreases the outlet air temperature. The Body Control Module (BCM) receives the input from the steering wheel controls. Pressing one of the steering wheel switches enables an in line resistor to drop voltage on the remote radio control signal circuit. The BCM then interprets this voltage signal and sends a class 2 message to the HVAC control module for the desired change. Page 10294 12. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 13. Adjust the front toe. Page 5039 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Specifications Differential Axle Housing: Specifications Rear Drive Axle Differential Housing Cover Bolts, 8.0" Axle ........................................................................................................................................ 30 Nm (20 ft. lbs.) Differential Housing Cover Bolts, 8.6" Axle ........................................................................................................................................ 25 Nm (18 ft. lbs.) Page 10009 1. Install new seals on the servo pistons and the servo cover. 2. Install the 2-4 servo assembly into the transmission. 3. Install the J29714-A. 4. Tighten the bolt in order to compress the servo cover. 5. Install the servo cover retaining ring. 6. Remove the J29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil pan bolt. ^ Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield. Notice: Refer to Fastener Notice in Service Precautions. Page 10010 9. Install the two bolts securing the transmission heat shield to the transmission. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 10. Install the exhaust pipe assembly. 11. Install the transmission support. 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON-III transmission fluid. Page 3517 For vehicles repaired under warranty, use the table. Disclaimer Page 983 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 5478 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Lift Gate Window Liftgate Window Glass Weatherstrip: Service and Repair Lift Gate Window REMOVAL PROCEDURE 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. INSTALLATION PROCEDURE 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Page 4558 Electrical Symbols Part 5 Page 8470 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 9367 Fuse Block - Rear C3 Page 3647 Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 4296 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5734 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 2844 Vehicle Lifting Points 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center 1. Lower Control Arm; Inboard of the Lower Ball Joint 1. Lower Control Arm; Inboard of the Lower Ball Joint 2. Frame; at Second Crossmember 2. Frame; at Second Crossmember 3. Rear Spring; at Forward Spring Hanger 3. Rear Spring; at Forward Spring Hanger 4. Axle; Inboard of Shock Absorber Hanger 4. Axle; Inboard of Shock Absorber Hanger 5. Differential; at Center 6. Front Suspension Crossmember; Center Page 12075 Garage Door Opener Transmitter: Description and Operation The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of Radio Frequency Interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the Body Control Module (BCM). Page 11815 Page 14411 1. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the rear seat cushion assembly. 3. Remove the pull handle assembly (1). 4. Remove the J-strips (2) securing the rear seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. Locations Locations View Page 5952 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9925 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 14685 4. Attach the molding to the outside of the door with double sided tape. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip. 9. Install the inner window belt sealing strip. 10. Install the trim panel. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. INSTALLATION PROCEDURE Page 15162 Engine Oil Pressure (EOP) Switch Page 11835 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 6108 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 387 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 1438 Engine Coolant Temperature (ECT) Sensor Page 6037 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Air Temperature Sensor Replacement - Upper Right Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Right REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. Programming Theft Deterrent System Components Alarm Module: Service and Repair Programming Theft Deterrent System Components IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the procedure to setup a new theft deterrent control module must be performed prior to the 10 Minute Re-Learn Procedure. TOOLS REQUIRED Tech 2 diagnostic scan tool Procedure to setup a New Theft Deterrent Control Module Use this procedure only if replacing the theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool, select Setup New VTD Module in the Vehicle Theft Deterrent, Special Functions data list. 4. Follow the scan tool on screen instructions. IMPORTANT: When replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, the module will learn keys immediately. The existing PCM however, must learn the new fuel continue password when the theft deterrent control module is replaced. - When replacing a powertrain control module (PCM) with a GM Service Parts Operation (SPO) Replacement Part, after programming, these modules will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, a relearn procedure must be performed to change this password again. A PCM which has been previously installed in another vehicle will have learned the fuel continue password of the other vehicles theft deterrent control module and will require performing the 10 Minute Re-Learn Procedure to learn the fuel continue password of the current vehicles theft deterrent control modules. - When performing the 10 Minute Re-Learn Procedure, all previously learned keys will be erased from the theft deterrent control module's memory. - Additional keys may be learned immediately after the 10 Minute Re-Learn Procedure. Refer to Adding Keys (Export). - When performing the 10 Minute Re-Learn Procedure, 2 master passkey III+ (PK3+) keys are required. If a gray valet key is learned first, the theft deterrent control module will not allow additional keys to be learned. TOOLS REQUIRED Tech 2 diagnostic scan tool - Techline Terminal with current Service Programming System (SPS) software 10 Minute Re-Learn Procedure Use this procedure after replacing any of the following components: The passkey III+ (PK3+) keys - The theft deterrent control module - The PCM, see Important above IMPORTANT: If replacing a theft deterrent control module with a GM Service Parts Operation (SPO) Replacement Part, insure the procedure to setup a new theft deterrent control module has been performed prior to the 10 Minute Re-Learn Procedure. 1. Connect the Tech 2 diagnostic scan tool to the vehicle. 2. With the scan tool, select Request Info. under Service Programming System and follow the scan tool on screen instructions. 3. Disconnect the scan tool from the vehicle and connect it to a Techline Terminal with current Service Programming System (SPS) software. 4. On the Techline Terminal, select Service Programming Systems and follow the Techline Terminal on screen instructions. 5. Disconnect the scan tool from the Techline Terminal and re-connect it to the vehicle. 6. With a master passkey III+ (PK3+) key, turn ON the ignition, with the engine OFF. 7. With the scan tool, select Program ECU under Service Programming System. 8. At this point the scan tool must remain connected for the duration of the 10 Minute Re-Learn Procedure. 9. Observe the SECURITY telltale or the scan tool on screen timer, after approximately 10 minutes the scan tool timer will expire and/or the telltale will turn off. The vehicle is now ready to relearn the key information and/or passwords on the next ignition switch transition from OFF to CRANK. 10. Turn OFF the ignition and wait 5 seconds. 11. With a master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the key transponder information and the PCM has now learned the fuel continue password. 12. Turn OFF the ignition and wait 15 seconds minimum. 13. With a second master passkey III+ (PK3+) key, start the vehicle, the theft deterrent control module has now learned the second master passkey III+ (PK3+) key transponder information. 14. Learning Additional keys, if required. Refer to Adding Keys (Export). 15. With the scan tool, clear any DTCs. Page 11919 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 11796 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 9380 Fuse Block: Service and Repair REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 4287 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 11496 11. Install the rear seat belt anchor to the seat belt buckle bracket with the nut. Tighten Tighten the rear seat belt anchor nut to 50 N.m (37 lb ft). 12. Install the rear seat back assembly. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the 3 screws securing the inboard rear seat back cushion latch cover. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 2. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 1750 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5270 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 15116 Electrical Symbols Part 7 Page 12519 Circuit/System Testing Component Testing Page 1440 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Page 6657 OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 6972 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Page 7843 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 16009 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 3. Disconnect the electrical connector from the sensor. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Page 985 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 4562 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 413 Driver Door Module (DDM) C3 Page 14987 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5838 Equivalents - Decimal And Metric Part 1 Page 11224 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 15357 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 15979 Electrical Symbols Part 7 Page 14673 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Remove the rear door sill plate. Front Axle Actuator Page 11882 For vehicles repaired under warranty use, the table. Disclaimer Page 15591 Electrical Symbols Part 7 Page 12902 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. INSTALLATION PROCEDURE 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location on the door according to the service hinge (4). 3. Drill a 3 mm (1/8 in.) pilot hole at each marked location (1). 4. Drill a 13 mm (1/2 in.) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901MD-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). 8. Hand tighten all four supplied bolts (4). 9. Align hinge. Page 9284 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 14931 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 7291 Valve Body: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 7381 Seals and Gaskets: By Symptom Technical Service Bulletin # 03-04-19-002B Date: 040404 Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Page 15849 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1528 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1014 For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of windshield wiper transmission seal assemblies required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of June 28, 2004 and will be approximately 20% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. CUSTOMER REIMBURSEMENT - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. CUSTOMER REIMBURSEMENT - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted by July 31, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Procedures Body Control Module: Procedures IMPORTANT: If the module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not property configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to Programming Theft Deterrent System Components in Theft Deterrent for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Air Suspension Sensor - LR Page 11619 Locations View Page 15991 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 152 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 6460 Page 14467 1. Install the seat latch rod (1) to the inner and outer riser assemblies. 2. Install a retainer nut (2) on each end of the seat latch rod (1). 3. Install the seat riser latch assembly (1) to the seat latch rod (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). Tighten Tighten the rear seat cushion bolts to 11 N.m (97 lb in). 5. Install the seat in the vehicle. Seat Riser Latch Assembly Replacement - Rear No. 2 REMOVAL PROCEDURE Page 10119 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Locations Locations View A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 11445 Since there are 8 different versions of seat belts used in this field action and an extremely small number of vehicles that will require the retractor replacement (less than 50 worldwide), part numbers are not listed in this bulletin and dealer listings are not broken down by color. Dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when inspection determines that it is necessary to replace a seat belt retractor. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For PC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and PC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL Page 15800 6. If replacing the reading lamp bulb (1), remove the reflector (2) from the dome lamp. 7. Remove the reading lamp bulb from the socket. 8. If replacing the dome lamp bulb (1), remove the dome lamp bulb from the socket. INSTALLATION PROCEDURE Page 4246 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10401 7. Install the shock module yoke to the shock absorber. 8. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten the shock module yoke to shock absorber pinch bolt to 70 Nm (52 ft. lbs.). 9. Install the shock module to the vehicle. 10. Install the tire and wheel. 11. Lower the vehicle. Shock Module Yoke Replacement Shock Module Yoke Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the shock module yoke to lower control arm mounting nut. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 3543 10. Unclip the fan shroud from the radiator at the side panels (1). 11. Tilt the radiator and the condenser forward. 12. Lift the fan and the shroud up and out towards the engine to release the fan from the radiator to clear the radiator inlet. Installation Procedure 1. Install the fan and the shroud onto the lip of the radiator bottom. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts into the upper fan shroud and tighten. ^ Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Connect the electrical connector. 4. Clip the fan shroud to the radiator at the side panels (1). Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 6305 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 10459 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 4769 Electrical Symbols Part 3 Page 1116 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Seat Switch Bezel Replacement REMOVAL PROCEDURE 1. Remove the 3 screws that retain the switch bezel to the seat. Procedures Body Control Module: Procedures IMPORTANT: If the module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not property configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to Programming Theft Deterrent System Components in Theft Deterrent for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 13045 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Page 15717 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 2527 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Locations Locations View Page 8997 1. Install the copper gaskets on the brake hose. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the brake caliper bolt to the brake caliper. Tighten Tighten the brake hose bolt to 44 N.m (32 lb ft). 3. Remove the plug or cap from the exposed brake pipe fitting. 4. Install the brake hose to the brake pipe. Important: Ensure that the brake hose is not twisted and does not come in contact with any of the suspension components. 5. Using a backup wrench on the brake pipe fitting, tighten the brake hose fitting. Tighten Tighten the brake hose fitting to 17 N.m (13 lb ft). 6. Install the brake pipe retaining clips. 7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Rear Brake Hose Replacement - Rear Removal Procedure Page 2045 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Page 13542 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 8265 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 7541 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 7278 Page 5768 Electrical Symbols Part 2 Page 1209 Locations View - HVAC Systems - Automatic Page 13433 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9345 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 14879 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 12504 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 266 Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Remove the left front door sill panel. 2. Remove the left closeout/insulator panel. 3. Remove the grille. 4. Remove the hood latch. 5. Release the hood latch release cable from the hood latch assembly. 6. Attach a length of mechanic's wire to the exterior end of the cable, and note the routing of the cable for later installation. 7. Release the retainer that attaches the cable to the hood hold open rod bracket. 8. Feed the cable out from between the headlamp panel and the radiator, then over the top of the battery tray. 9. Push the cable grommet (1) through the bulkhead and into the interior of the vehicle. 10. Remove the nut (2) attaching the hood release handle (3) to the cowl trim panel on the left side. 11. Remove the cable from the release handle (3). 12. Pull the cable the rest of the way through the bulkhead and out from behind the sound insulation. 13. Detach the mechanics wire from the cable, leaving the wire in position for aid in installation of the cable. 14. Remove the cable from the vehicle. Installation Procedure 1. Attach the mechanics wire to the exterior end of the cable. 2. Using the mechanic's wire as an aid, guide the cable underneath the sound insulation and pass the exterior portion of the cable through the Page 7035 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 265 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 15258 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4375 For vehicles repaired under warranty, use the table. Disclaimer Page 6786 Page 5172 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 13485 17. Remove the floor console to the floor console carrier. 18. Remove the 4 nuts (2) retaining the rear of the floor console bracket to the floor weld studs. 19. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 20. Remove the carpet from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. Page 3852 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 13115 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. Page 13718 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15769 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 8411 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Lumbar Adjuster Switch - Driver (W/Memory Seat) Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Body - Liftgate Glass Hard to Close Trunk / Liftgate Handle: Customer Interest Body - Liftgate Glass Hard to Close File In Section: 08 - Body and Accessories Bulletin No.: 03-08-66-006 Date: June, 2003 TECHNICAL Subject: Lift Gate Glass Hard to Close (Replace Weatherstrip and Shim Handle) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the lift gate glass is hard to close. Cause The weatherstrip may be too stiff and the glass bounces back when closing. Correction Replace the weatherstrip and shim the lift gate window handle. 1. Remove the garnish molding from the lift gate for easy access to the weatherstrip. 2. Remove the lift gate weatherstrip. 3. Install the lift gate glass weatherstrip. 4. Install the garnish molding. 5. Loosen the two nuts that retain the handle and the striker to the glass and install the shim between the glass and the striker. Tighten Tighten the nuts to 6 N.m (53 lb in). Important: Page 2205 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1862 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 65 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 158 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1307 Electrical Symbols Part 2 Page 5690 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4291 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 6436 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 5255 Electrical Symbols Part 3 Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Diagrams Hood Ajar Switch (Export) Capacity Specifications Refrigerant System Capacities Page 1631 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. Page 14736 Electrical Symbols Part 5 Page 6032 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 2024 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8655 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 5975 Electrical Symbols Part 5 Page 5498 Fuel Injector Balance Test With Tech 2 - Steps 6-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 4. The fuel pressure should be within the specified range. Refer to Fuel System Diagnosis if the fuel pressure is not within the specified range. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 5. The fuel pressure should reach a steady value. Refer to Fuel System Diagnosis if the fuel pressure does not stabilize. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Page 4148 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13439 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9196 1. Install the new positive cable to the generator and secure the positive cable with the nut (1). Tighten Tighten the positive cable bolt to 9 N.m (80 lb in). 2. Connect the positive cable to the junction block and secure the positive cable with the bolt. Tighten Tighten the positive cable nut to 10 N.m (89 lb in). 3. Connect the positive cable to the starter and secure the positive cable with the nut. Tighten Tighten the nut 9 N.m (80 lb in). 4. Connect the harness to the engine harness bracket. 5. Connect the cable to the positive battery post. Tighten Tighten the battery positive bolt to 15 N.m (11 lb ft). 6. Connect the battery negative cable. Page 8630 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 15504 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9657 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 1667 Equivalents - Decimal And Metric Part 1 Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 10659 1. Remove the I/P carrier. 2. Remove the left side air temperature actuator (1) retaining screws. 3. Disconnect the left side air temperature actuator electrical connector. 4. Remove the left side air temperature actuator. INSTALLATION PROCEDURE 1. Install the left side air temperature actuator (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the left side air temperature actuator retaining screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the left side air temperature actuator. 4. Install the I/P carrier. 5. Calibrate the air temperature actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Right REMOVAL PROCEDURE Page 15734 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 11702 Holding the Select button for longer than 3 seconds while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: ^ Range - Can not be reset ^ Avg. Fuel Economy - Can be reset ^ Inst. Fuel Economy - Can not be reset ^ Engine Oil Life - Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0 - 999 MI or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 3 seconds while the Average Fuel Economy is displayed in the DIC will reset both the Trip Distance and Trip Fuel Used to 0.0. Average Fuel Economy is capable of displaying values from 0.0 to 99.9. Display appears as: AVG MPG XX.X (English), AVG L/100 km XX.X XX (Metric), AVG km/l XX.X (Japanese). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 to 99.9. Display appears as INST MPG XX.X (English), INST L/100 km XX.X (Metric), INST km/l XX.X (Japanese). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100%. Display appears as ENGINE OIL LIFE: XXX%. FEATURE PROGRAMMING Refer to Personalization Description and Operation. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Page 15118 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Audio System - Whine/Buzz Noise on Acceleration Technical Service Bulletin # 02-08-44-016A Date: 021201 Audio System - Whine/Buzz Noise on Acceleration File In Section: 08 - Body and Accessories Bulletin No.: 02-08-44-016A Date: December, 2002 TECHNICAL Subject: Whine, Buzz, Generator Whine, Whine Type Noise Heard on Acceleration (Repair Vehicle Sound System Wiring) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to December, 2001 This bulletin is being revised to change the model year. Please discard Corporate Bulletin Number 02-08-44-016 (Section 08 - Body and Accessories). Condition Some customers may comment on a buzzing or generator whine-type noise that emanates from the vehicle speakers with the radio on or off and when the headlights are on. This sound may be altered by changing the IP backlighting intensity (Dimming Function). Or, a noise emanates from the All-Wheel Drive system (if equipped), of 1 to 2 seconds duration during initial acceleration, at 24 km/h (15 mph) or at 48 km/h (30 mph). The generator whine-type noise may be observed at any time, however it is more noticeable when the electrical load on the system is high. Cause The cause of this condition may be EMI interference that is being transmitted to the radio system speakers from within the body wiring harness. Correction To determine which parts to order, you will need to inspect the vehicle. There are four types of audio systems available and three specific service wiring harness assemblies. ^ Bose(R) Premium Sound System with Rear Audio Controls ^ Bose(R) Premium Sound System without Rear Audio Controls ^ Non-Bose(R) Sound System with Rear Audio Controls ^ Non-Bose(R) Sound System without Rear Audio Controls See the Parts Information below for applicable part numbers. Parts Information Paris are currently available from GMSPO. Warranty Information Page 2431 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE Page 14763 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8059 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Page 15922 License Plate Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 12234 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Electronic Brake Control Module (EBCM) C1 Page 5516 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This can be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Page 1964 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 3955 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 16018 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the electrical connector and remove the stoplamp switch (1). Installation Procedure 1. Install the electrical connector on the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Page 10153 For vehicles repaired under warranty, use the table. Disclaimer Page 7623 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 5457 Electrical Symbols Part 5 Page 14828 Electrical Symbols Part 5 Page 7292 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 814 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet Trailblazer, Envoy, and Bravada TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater Inlet hoses. Page 7647 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 14561 Air Dam: Service and Repair Air Intake Baffle Replacement - Radiator Air Intake Baffle Replacement - Radiator Removal Procedure 1. Open the hood. 2. Remove the push-pins that retain the baffle. 3. Remove the bolts that retain the baffle to the radiator support. 4. Remove the radiator baffle from the vehicle. Installation Procedure 1. Position the baffle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the baffle to the body. Tighten the air intake baffle bolts to 2 N.m (18 lb in). 3. Install the push-pin retainers. Page 915 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 12643 Disclaimer Page 14383 9. Using a flat-bladed tool, carefully disengage the plastic strips that retain the seat back cover to the side airbag inflator module cover. 10. Carefully remove the seat back cover from behind the trim edge of the side airbag inflator module. 11. Compress the seat back pad in order to relieve the pressure against the seat cover. 12. Using a side to side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. IMPORTANT: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the pad. 13. Release the lower Velcro retaining strips located inside the seat cover. 14. Remove the 3 hog rings that retain the seat back pad to the reinforcement bar located at the top of the seat back. Page 9435 For vehicles repaired under warranty, use the table. Disclaimer Page 15986 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15983 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Service and Repair Front Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the front half of the water deflector in order to expose the door access hole. 3. Remove the 2 bolts that retain the check link to the pillar. 4. Remove the rubber dust boot from the check link in order to gain access to the door retaining nuts. 5. Remove the 2 check link retaining nuts from the door. 6. Remove the check link assembly through the door access hole. Installation Procedure Page 5463 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 12092 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Page 6789 Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. Important: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. 6.1. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. 6.2. Remove the 1-2 accumulator inner and outer springs. 7. Inspect the 1-2 accumulator inner and outer springs for cracks. Page 6945 Fluid Line/Hose: Specifications Cooler Pipe Connector ............................................................................................................................................................. 35.0-41.0 Nm (26-30 ft. lbs.) Transmission Oil Cooler Pipe Fitting ....................................................................................................................................... 35.0-41.0 Nm (26-30 ft. lbs.) Page 15614 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9309 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 3970 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10936 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to join the HVAC module assembly halves. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the HVAC module assembly. Page 11454 Page 1248 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 15069 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Page 13169 Disclaimer Page 4773 Electrical Symbols Part 7 Page 4865 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 3685 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1704 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 12970 Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Front Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten the retaining bolts to 10 N.m (88 lb in). 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 5661 Fuel Tank Unit: Description and Operation Fuel Sender Assembly The fuel sender assembly consists of the following major components: ^ The fuel pump (1) ^ The float (2) ^ The fuel level sensor (3) Page 8952 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 10632 Defrost Actuator Recirculation Actuator Page 14849 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 1714 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 9466 C306 C307 Part 1 Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator Retainer Screw 8 N.m Vacuum Module Attaching Bolts 8 N.m Specifications Piston Pin: Specifications Piston & Pin Piston Diameter - (1.4961 inch) down from top 3.6627-3.6633 inch Piston to Bore Clearance 0.0004-0.0017 inch Piston to Pin Clearance 0.00012-0.0005 inch Pin Bore 0.9056-0.9058 inch Piston Pin Diameter 0.9054-0.9055 inch Page 3608 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 6743 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 7. Install the motor/encoder to the transfer case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 8. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 9. Connect the motor/encoder electrical connector (1). 10. Install the fuel tank shield, if equipped. 11. Lower the vehicle. Page 5543 the locking tabs. 5. Pull the connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal Injury, before connecting fuel pipe fittings, always apply a few drops Of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-ring located in the female connector will swell and may prevent proper reconnection If not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fitting together in order to snap the retaining tabs into place. Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint Lower Ball Joint Replacement Tools Required ^ J9519-E Ball Joint Remover and Installer Set ^ J34874 Booster Seal Remover/installer ^ J41435 Ball Joint Installer ^ J45105-1 Ball Joint Flaring Adapter ^ J45105-2 Receiver Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the steering knuckle with wheel hub and bearing attached. 4. Remove the lower ball joint flange with a chisel. 5. Install J9519-E and J34874 to the lower ball joint. 6. Remove the lower ball joint from the lower control arm using J9519-E and J34874. Installation Procedure Page 9263 For vehicles repaired under warranty, use the table. Disclaimer A/C - Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3042 6. Remove the right and the left upper engine mount nuts. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the right and the left lower engine mount nuts. 9. Remove the engine protection shield mount bolts. 10. Remove the engine protection shield. Important: When placing jack onto the oil pan, pay close attention to not damage the oil level sender. 11. Lower the vehicle and place a floor jack under the oil pan with a block of wood. 12. Raise the engine with the jack just enough to clear the engine mount studs. 13. Remove the left engine mount from the bracket. Page 791 Electrical Symbols Part 5 Page 15349 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Locations Locations View Page 12873 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 11828 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 8320 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 16003 Equivalents - Decimal And Metric Part 1 Locations Page 1407 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 13953 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 12813 Front Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 02-08-62-004B Date: 060602 Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. Page 12907 7. Pass the feed wire (1) through the hinge (2), the body pillar (3), and the backing plate (4). 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire (1) while guiding the backing plate (2) into the inner structure. 10. Place the hinge (1) into position and hand tighten the two attaching bolts. 11. Remove the feed wire (1) from the hinge. Page 4732 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2(TM). 33. If a control module is replaced the following service procedures must be performed: - The Crankshaft Variation Learn Procedure - The Engine Oil Life Reset Procedure - The Idle Learn Procedure - The Inspection/Maintenance Complete System Set Procedure - The Vehicle Theft Deterrent Password Learn Procedure - The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: Ensure the control module and DLC connections are OK. - Ensure the Techline(TM) operating software is up to date. - Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. - The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2(TM) to communicate with the control module. - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: The Off-Board Programming Adapter - The Tech 2(TM) - The control module - The Techline(TM) terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline(TM) terminal, select Service Programming. 3. Select Tech 2(TM), Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(TM) as described on the Techline(TM) terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2(TM), select Service Programming Request Information function. The Tech 2(TM) communicates with the control module and receives the access code. 6. With the Tech 2(TM), exit the Service Programming Request Information. 7. Disconnect the Tech 2(TM) from the Off-Board Programming Adapter. 8. Connect the Tech 2(TM) to the Techline(TM) terminal. 9. Turn ON the Tech 2(TM). 10. With the Techline(TM) terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline(TM) terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline(TM) terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline(TM) terminal automatically loads the calibration files to the Tech 2(TM). 16. After the download is complete, turn OFF the Tech 2(TM) 17. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 18. Connect the Tech 2(TM) to the Off-Board Programming Adapter. 19. With the Tech 2(TM), select Service Programming. Page 13246 Trunk / Liftgate Handle: Service and Repair HANDLE/STRIKER REPLACEMENT - LIFT GATE WINDOW REMOVAL PROCEDURE 1. Open the lift gate window. 2. Remove the nuts retaining the striker assembly to the lift gate window. 3. Remove the handle and striker assembly from the lift gate window. INSTALLATION PROCEDURE 1. Install the handle and striker assembly to the lift gate window. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the striker assembly to the lift gate window. Tighten Tighten the nuts to 6 N.m (53 in lb). 3. Check the lift gate window for proper operation, adjust if necessary. Refer to Striker Adjustment Lift Gate Window. Page 14968 Electrical Symbols Part 7 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 4867 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 8790 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Page 815 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 15617 Various symbols are used in order to describe different service operations. Page 2939 2. Install the coolant heater cord to the battery cover (1). 3. Install the PCM. Page 15790 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15289 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 14204 For vehicles repaired under warranty, use the table. Disclaimer Page 14414 Tighten Tighten the seat cushion bolts to 11 N.m (97 lb in). Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ......................................................... 1.8 lb. (0.8 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Page 14786 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 5093 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 4001 Electrical Symbols Part 5 Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5043 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5238 Equivalents - Decimal And Metric Part 1 Radiator Cleaning Radiator: Service and Repair Radiator Cleaning Radiator Cleaning Caution: NEVER spray water on a hot radiator. The resulting steam could cause personal injury. Notice: The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Important: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. ^ Some conditions may require the use of warm water and a mild detergent. ^ Clean the A/C condenser fins. ^ Clean between the A/C condenser and radiator. ^ Clean the radiator cooling fins. ^ Straighten any damaged cooling fins. Page 1979 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7556 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 9318 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. A/C Refrigerant System Oil Charge Replenishing Refrigerant Oil: Service and Repair A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (fart). Page 11738 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6422 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 12667 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 6664 For vehicles repaired under warranty, use the table. Disclaimer Page 10127 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12140 Locations View Page 14447 Heated Seat Element - Front Passenger Cushion Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 10664 1. Remove the floor console. 2. Rotate the console. 3. Remove the screw from the air outlet duct. 4. Remove the air outlet duct from the floor console. 5. Remove the rear mode actuator retaining screws. 6. Disconnect the electrical connector. 7. Remove the rear mode actuator. INSTALLATION PROCEDURE Page 13688 Electrical Symbols Part 2 Page 5584 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 5779 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Malfunction Indicator Lamp (MIL) Always On - Steps 1-6 Page 14779 Electrical Symbols Part 8 Page 5403 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Page 7428 For vehicles repaired under warranty, use the table. Disclaimer Page 6052 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 4834 Disclaimer Page 9525 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 12305 Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 4214 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 509 Page 4087 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 14859 Cigar Lighter/Auxilary Outlets Schematics Page 3057 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the idler pulley bolt from the idler pulley bracket. 3. Remove idler pulley. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the idler pulley and secure the pulley with the bolt. ^ Tighten the idler pulley bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Page 3051 ^ Tighten the upper engine mount nuts to 70 Nm (52 ft. lbs.). 7. Raise the vehicle and remove the floor jack from under the vehicle. 8. Install the engine protection shield and secure with the bolts. ^ Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 9. Install the right and the left lower engine mount nuts. ^ Tighten the lower engine mount nuts to 70 Nm (52 ft. lbs.). 10. Lower the vehicle. 11. Install the right shock module. 12. Install the MAP sensor (2). 13. Install the MAP sensor retainer (1) and the electrical connector. Page 4507 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 12354 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 149 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 581 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Page 12094 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Remove the rear hood seal from the inlet grille panel studs. 3. Remove the seal from the inlet grille panel. Installation Procedure 1. Position the seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Close the hood. Page 4767 Electrical Symbols Part 1 Page 226 Page 9650 Fuse Block - Underhood C2 Part 2 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 14073 Endgate Module (EGM) C2 (XUV) Part 1 Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 8133 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 1541 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3230 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 11802 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 13606 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. INSTALLATION PROCEDURE 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Door Sill Plate Replacement - Lift Gate REMOVAL PROCEDURE Page 8576 For vehicles repaired under warranty, use the table. Disclaimer Body - Liftgate Glass Unlatches On Bumpy Roads Tailgate Latch: Customer Interest Body - Liftgate Glass Unlatches On Bumpy Roads Bulletin No.: 04-08-66-004A Date: June 22, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Liftgate Glass Unlatches on Rough/Bumpy Road Surfaces (Replace Liftgate Window Latch) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to provide the correction and warranty information, which is now available for Advanced Service Bulletin Number 04-08-66-004. Please discard Corporate Bulletin Number 04-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear liftgate window unlatches when driving on rough/bumpy road surfaces. This condition may be very difficult to duplicate. Cause The liftgate window latch may be the cause of this condition. Correction Replace the liftgate window latch. Refer to the Liftgate Window Latch Replacement procedure in the Body Rear End sub-section of the Service Manual. Part Information Parts are expected to be available from GMSPO on June 25, 2004. Warranty Information For vehicles repaired under warranty, use the table. Page 9777 C308 C309 (Long Wheelbase Body,Type VIN 6) Part 1 Page 15315 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Page 10414 7. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 8. Remove the ABS sensor from the wheel hub and bearing. 9. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 10. Remove the wheel hub and bearing from the steering knuckle. 11. Remove the splash shield from the steering knuckle. Installation Procedure Page 3596 Electrical Symbols Part 8 Page 12053 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11671 Electrical Symbols Part 6 Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: Customer Interest Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 11355 Seat Belt: Technician Safety Information CAUTION: ^ To help avoid personal injury from unrepaired crash damage to a restraint system, perform the seat belt check for each seat belt system. Replace the seat belt system If there is any doubt about the condition Of system components. ^ A child in a rear-facing child restraint can be seriously injured if the right front passengers air bag inflates. This is because the back Of a rear-facing child restraint would be very close to the inflating air bag. NEVER use a rear-facing child restraint in this vehicle. If a forward-facing child restraint is suitable for your child, ALWAYS move the front passenger seat as far back as it will go and then Install the child restraint. Be sure the child restraint position does not conflict with any additional requirements provided by the manufacture. For more information, refer to the vehicle owners manual and the instruction that came with the child restraint. ^ Perform this test in an area clear Of other vehicles or obstructions. Do not conduct this test on the open road. A large, empty parking lot is suitable. Failure to observe this precaution may result in damage to the vehicle and possible personal injury. ^ Restraint Systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: ^ Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people Of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. ^ Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. ^ Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. ^ Replace any seat belt system if you are doubtful about Its condition. This not only Includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been In a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. Seat Belt Service Precautions ^ Do not bleach or dye the seat belt webbing. Use only the following items in order to clean the seat belt webbing: ^ A mild soap and water solution ^ A soft brush or cloth ^ Keep sharp edges and damaging objects away from the seat belts. Do not bend or damage any part of the seat belt buckle or latch plate. Replace any seat belts that are cut or otherwise damaged in any manner. ^ Use only the correct seat belt anchor fasteners. Begin tightening the seat belt anchor fasteners by hand in order to ensure that the bolt is threaded straight. Tighten the correct seat belt anchor nut to the correct torque value. Refer to Fastener Tightening Specifications. ^ Some seat belts and retractors require service as a set with service replacement components only. Do not repair individual components that require service as a set. ^ Verify that the replacement part number is correct for the vehicle at that seating position. Do not substitute a seat belt from a different seating position. ^ Replace any seat belts that have a visible Caution label instructing replacement. ^ Some seat belts have an Energy Management Loop. An Energy Management Loop is an overlap of the seat belt webbing that is stitched together. If any separated stitching exists, replace the seat belt. Page 14891 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Page 8542 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 5662 Fuel Tank Unit: Service and Repair TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 2. Use the J 44402 to remove the fuel sender assembly retaining ring. 3. Remove the fuel sender assembly and the seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel In an open container. 4. Clean the fuel sender sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Install the new seal on the fuel tank. Page 12746 INSTALLATION PROCEDURE IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. Page 9857 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the park brake as firmly as possible, depress Auto Trans Shift Lock Control solenoid plunger and pull the shift lever to the L1 position. 15. Lift the console, disconnect the console wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (Trail Blazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (Except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward arid disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Brown/White wire. ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio in the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place it under the carpet to the area of the rear audio control and reposition the carpeting. Page 14992 Equivalents - Decimal And Metric Part 1 Page 15097 Odometer: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 14511 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Page 6811 Band Apply Servo: Service and Repair 2-4 Servo Removal Procedure ^ Tools Required J 29714-A Servo Cover Depressor 1. Raise the vehicle. Refer to Vehicle Lifting 2. Support the transmission with a suitable jack. 3. Remove the transmission support. Refer to Transmission Support Replacement on page 8-1405 in Frame and Underbody. 4. Remove the front exhaust pipe assembly. 5. Remove the heat shield. 6. Carefully lower the transmission to gain access to the 2-4 Servo. 7. Install the J29714-A. 8. Tighten the bolt in order to compress the servo cover. Page 11477 6. Remove the seat belt anchor nut. 7. Remove the screw that attaches the seat belt bezel to the seat back. 8. Remove the seat belt material from the bezel. 9. Release the J-strips (1, 4) across the bottom of the seat back cover. 10. Remove the push pins (3) securing the seat cover (2) to the seat frame. 11. Remove the head restraint. 12. Using a flat-bladed tool, carefully disengage the plastic strips or channels that retain the seat back cover to the side impact airbag module. Page 2308 Disclaimer Page 583 Page 8707 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9221 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4017 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Service and Repair Glove Compartment: Service and Repair DOOR REPLACEMENT - INSTRUMENT PANEL (I/P) COMPARTMENT REMOVAL PROCEDURE 1. Remove the right closeout/insulator panel. 2. Remove the 3 storage compartment retaining screws. 3. Remove the storage compartment from the IP. INSTALLATION PROCEDURE 1. Position the storage compartment to the IP. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 screws. Tighten Tighten the screws to 2.5 N.m (22 lb in). 3. Install the right closeout/insulator panel. Page 8608 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 15697 Center High Mounted Stop Lamp (CHMSL) Page 11269 11. When deploying the side impact module-left, refer to the following instructions: ^ Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area. ^ Fill the deployment fixture with water or sand. ^ Mount the side impact module-left (1) in the deployment fixture (3) with the vinyl/plastic trim cover facing up. ^ Adjust and secure the J 39401-B arms (4) to the deployment fixture (3). ^ To mount, use 2 m 6 x 1.0 nuts (2) with washers in order to secure the side impact module-left (1) to the deployment fixture arms (4). ^ Securely tighten all fasteners prior to deployment. 12. Inspect the J 38826 SIR deployment harness (1) and the appropriate pigtail adapter (2) for damage. Replace as needed. 13. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other. 14. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). Page 11049 1. Install the O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Page 8708 Page 12130 Disclaimer Page 4803 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5786 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1525 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9339 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 6421 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Page 13514 Disclaimer Page 15860 1. Position the bulb and socket to the headlamp. 2. Connect the electrical connector to the socket. 3. Install the bulb and socket to the housing by rotating the bulb and socket clockwise, locking the retaining tabs to the housing. 4. Install the access cover to the rear of the headlamp assembly 5. Install the headlamp. Page 12938 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 5159 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5045 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12909 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Door Side Hinge Replacement - Front Door - Door Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the 4 weld locations. Page 3046 14. Connect the cooling fan hub nut to the water pump shaft. 15. Install the J41240 to the water pump pulley and tighten the cooling fan hub nut. ^ Tighten the hub nut to 56 Nm (41 ft. lbs.). 16. Connect the battery negative cable. Page 11086 Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Automatic A/C LOW PRESSURE SWITCH A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 15130 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Locations Locations View Page 1664 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 6409 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 9366 Fuse Block - Rear C2 Part 2 Suspension - Boom/Rumble Heard at Highway Speeds Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Boom/Rumble Heard at Highway Speeds Bulletin No.: 02-03-09-002C Date: December 06, 2004 TECHNICAL Subject: Intermittent Boom, Rumbling Noise and/or Disturbance Heard in Passenger Compartment While Driving at Highway Speeds (Replace Rear Coil Springs) Models: 2002-2005 Chevrolet TrailBlazer 2002-2005 GMC Envoy with Rear Coil Springs 2003-2004 Oldsmobile Bravada with Rear Coil Springs Built Prior to August 23, 2004 (Refer to Parts Information table below for applicable RPO Code usage) Attention: Do not perform this bulletin for vehicles built after 8/23/04. Supercede: This bulletin is being revised to add the breakpoint of 8/23/2004 for 2005 model year production with an updated spring material. Please discard Corporate Bulletin Number 02-03-09-002B (Section 03 - Suspension). Condition Some customers may comment on an intermittent booming, rumbling noise and/or disturbance heard in the passenger compartment while driving the vehicle at highway speeds. This condition occurs while driving at steady speeds between 1550-1700 engine RPM in 4th gear (NOT during acceleration). This equates to 64-80 km/h (48-50 mph) for vehicles with a 4.10 axle ratio (RPO GT5), 83-86 km/h (52-54 mph) with a 3.73 axle ratio (RPO GT4) and 93-96 km/h (58-60 mph) with a 3.42 axle ratio (RPO GU6). Cause The noise/disturbance occurs when the torque converter momentarily goes to a full lock-up state, resulting in zero slip of the torque converter. When the torque converter returns to normal ECCC mode with 30 RPM of slip, the noise will go away. The disturbance generated by the zero slip condition is amplified and transferred into the passenger compartment by the rear coil springs. Correction Replace the rear coil springs using the following service procedure. Note: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. 2. Support the front frame rail of the vehicle with a suitable adjustable jack stand. 3. Support the rear axle with a suitable adjustable jackstand. 4. Remove the two shock absorber lower mounting bolts. 5. Lower the rear axle enough to remove the tension on the rear coil springs. 6. Remove the rear coil springs. Important: ^ It is critical that the correct coil springs are installed in the correct location. Page 11728 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 3382 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13959 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 4424 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 13643 8. Partially remove the trim panel in order to remove the inflator switch from the inflator bezel. 9. Remove the auxiliary air outlet washer and retaining nut. 10. Feed the auxiliary air outlet through the inflator bezel. 11. Remove the inflator bezel from the trim panel. 12. Disconnect the the 12-volt power supply electrical connector. 13. Remove the 12-volt power supply. 14. Remove the trim panel from the vehicle. Installation Procedure 1. Position the trim panel to the vehicle. 2. Install the 12-volt power supply. 3. Connect the 12-volt power supply electrical connector. 4. Install the inflator bezel to the trim panel. 5. Feed the auxiliary air outlet through the hole in the inflator bezel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the auxiliary air outlet washer and retaining nut. Tighten the nut to 2 N.m (18 lb in). 7. Install the inflator switch to the inflator bezel. 8. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 9. Align the locating tabs on the trim panel to the holes in the body. 10. Seat the clips that retain the trim panel to the body. 11. Install the seat belt lower anchor. Tighten the anchor bolt to 70.0 N.m (52 lb ft). 12. Install the right rear door sill panel. 13. Install the liftgate sill plate. 14. Install the trim panel-rear quarter upper. Trim Panel Replacement - Rear Quarter Upper (TrailBlazer, Envoy, Bravada) Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 5494 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool CIRCUIT Fuel Injector Balance Test With Special Tool Injector Balance Test Example TEST DESCRIPTION Page 11513 5. Loosen the bolts (1) retaining the discriminating sensor to the frame. 6. Remove the discriminating sensor assembly from the frame (1). 7. Position the discriminating sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the discriminating sensor. 9. Remove the connector-position assurance (CPA) from the discriminating sensor electrical connector. Page 14803 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 4771 Electrical Symbols Part 5 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 3597 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 7786 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 1474 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 1688 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 6814 9. Install the two bolts securing the transmission heat shield to the transmission. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 10. Install the exhaust pipe assembly. 11. Install the transmission support. 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON-III transmission fluid. Page 15288 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 1415 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 2443 1. Install the new O-ring seal. 2. Install evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the evaporator tube to the evaporator (5). Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 6. Install the coolant recovery tank. 7. Install the washer solvent container. 8. Install the nuts (1,2) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400. HVAC Systems - Manual Blower Motor Switch: Service and Repair HVAC Systems - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 8217 Page 15043 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 7378 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 13689 Electrical Symbols Part 3 Page 4703 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 6769 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 6361 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4751 Data Link Connector (DLC) Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3999 Electrical Symbols Part 3 Page 15522 Conversion - English/Metric Page 1059 Passlock Sensor Page 14128 12. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 13. Rotate and clip the sunshade to the inboard retainer. 14. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 15. Install the front assist handle to the roof panel. Refer to Assist Handle Replacement. 16. Install the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar. 17. Install the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 18. Return the bucket seat to an upright position. Page 13316 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... ................................................ 140 Nm (103 ft. lbs.) Page 1641 Electrical Symbols Part 5 AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 14522 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Page 14296 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 10958 Heater Control Valve: Description and Operation HVAC Systems - Automatic COOLANT BYPASS VALVE The coolant bypass valve controls coolant flow to the auxiliary heater core. Integral to the coolant bypass valve is an electric solenoid that controls vacuum flow to open and close the valve. When the HVAC control module applies 12 volts to the integral solenoid, the solenoid applies vacuum to a diaphragm that closes the water valve. This action restricts coolant flow to the auxiliary heater core. The coolant bypass valve is a normally open valve. If there is a concern with control of the valve or with its vacuum source the valve will still be able to supply heated coolant to the auxiliary heater core. Page 9878 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 11928 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 934 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 14237 Locations View Page 7152 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 12735 Parts are currently available from GMSPO. Disclaimer Page 799 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 9627 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet - Console Auxiliary Power Outlet - Rear Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 14248 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the seat control module to the seat pan. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Page 6733 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 15659 area. Important: ^ Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the lift gate glass. ^ Do not wipe the glass dry. ^ Allow the liftgate glass to air dry completely. ^ The applique must be installed within 30 minutes following the use of the promoter. 16. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. 17. Attach the CHMSL wire to the connector and install the grommet. 18. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. 19. Remove the protective liner from the tape on the applique. 20. Attach the locating hooks on the applique to the hinge pins. 21. Apply the applique to the liftgate glass. 22. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure ensuring complete contact of the adhesive strip to the glass. 23. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). Important: The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. 24. Clean the liftgate glass and applique area. Parts Information Parts are currently available from GMSPO. Warranty Information Page 6705 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5423 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Page 6775 Page 1106 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Fuse Block - Rear Fuse Block: Locations Fuse Block - Rear Fuse Block Rear Locations View Located under the left rear seat. Page 12426 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 394 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 3906 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Inflate the tire to the manufactures specified pressure as stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5. Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 7. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 10. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the valve stem on the wheel. 13. Install the tire to the wheel. 14. Inflate the tire to the manufactures specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 16. Balance the tire and wheel. 17. Install the tire and wheel. 18. Lower the vehicle. Recall - Tail/Stop Lamp Inspection/Replacement Technical Service Bulletin # 04087 Date: 041116 Recall - Tail/Stop Lamp Inspection/Replacement Product Safety - Tail Lamps/Stop Lamps # 04087 - (Nov 16, 2004) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles. In some of these vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. The center high mounted stop lamp and turn signal functions are not affected and will operate as designed. The loss of one or both of the tail lamp/stop lamps could reduce the vehicle's visibility to following drivers and fail to warn others that the vehicle is braking and/or is stopped, which could lead to a vehicle crash. Correction Dealers are to inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. Vehicles Involved Involved are certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US Page 14292 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Seat Switch Bezel Replacement REMOVAL PROCEDURE 1. Remove the 3 screws that retain the switch bezel to the seat. OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 16042 Turn Signal/Multifunction Switch C2 Turn Signal/Multifunction Switch C3 Page 769 Powertrain Control Module (PCM) C2 Part 2 Page 5911 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 9870 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 5715 Accelerator Pedal Position (APP) Sensor Page 2407 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 8200 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 16008 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 6959 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4889 Various symbols are used in order to describe different service operations. Page 4395 Electrical Symbols Part 6 Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 2948 DISCLAIMER Page 8058 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 12047 Electrical Symbols Part 8 Page 3908 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 13583 34. Disconnect the electrical connector from the right-hand body side window actuator. 35. Disconnect the electrical connector from the left-hand body side window actuator. 36. Remove the windshield rearview mirror wire harness cover. 37. Disconnect the inside rear view mirror electrical connector (3). 38. Disconnect the rain sensor electrical connector (2), if equipped. 39. Disconnect the coax cable (1) from the navigational antenna, if equipped. 40. Remove the bolt securing the auxiliary air conditioning duct to the vehicle. 41. Remove the 2 push pins (2,3) from the rear of the headliner. 42. Remove the 3 push pins from the rear of the headliner. 43. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 44. With the aid of an assistant, lower the headliner to release the interlocking strips (1) that retain the headliner to the roof panel. A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 9754 Parts Information Parts are expected to be available 8-22-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12531 Page 5767 Electrical Symbols Part 1 Page 35 Page 14925 Electrical Symbols Part 7 Page 8914 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 4967 Electrical Symbols Part 6 Locations Locations View - HVAC Systems - Manual Page 15905 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 6264 5. Remove the motor/encoder assembly. Important: When replacing the encoder rotary position sensor follow these additional steps. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder gasket. 6. Position the motor on a work bench. 7. Release the 4 tabs that retain the motor/encoder gasket and remove the gasket (1). 8. Remove the snap ring and washer retaining the motor/encoder rotary position sensor. Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed. 9. Lift the motor/encoder rotary position sensor (2) from the motor shaft. 10. Disconnect the rotary position sensor (2) from the wiring harness. Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed. Installation Procedure Important: Provided the rotary position sensor was removed, follow steps to install the sensor, otherwise proceed to installing the motor/encoder to the transfer case. 1. Connect the wiring harness to the rotary position sensor. 2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed. Page 5275 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 12163 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 9490 C311 C312 Part 1 Page 5616 On some 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles currently or previously registered in the corrosion areas shown above, the fuel tank modular reservoir assembly, which contains the fuel pump, may develop corrosion of the fuel feed/return pipes after an extended period of time. Severe corrosion may cause the formation of small perforations. These perforations may allow a small amount of fuel to accumulate in a recessed area outside of the fuel tank. If this were to occur, it would be accompanied by a fuel odor. If left uncorrected and the corrosion is allowed to progress, a fuel spray from the pipes may begin to occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to replace the fuel tank modular reservoir. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 30, 2008, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 30, 2008, must be submitted to the Service Contract provider. Vehicles Involved Page 13595 Rear. 26. Install the video display. 27. Attach the mechanic's wire to the end of the headliner harness positioned behind the IP. 28. Pull the bottom of the mechanic's wire away from the cowl insulation access hole in order to position the headliner harness behind the IP. 29. Attach the 3 clips (1) securing the wire harness to the windshield pillar. 30. Attach the lower rosebud (2) retaining the headliner harness to the cowl. 31. Connect the coax cable (2) and headliner harness connector (1). 32. Close the IP compartment door. 33. Install the right sound insulator. 34. Install the IP trim pad. 35. Install the windshield garnish moldings. 36. Install the center pillar trim panels. 37. Install the rear side door sill plates. 38. Install the front side door sill plates. 39. Install the rear seats. 40. Install the luggage/cargo shelf assembly, if equipped. 41. Install the cargo net, if equipped. Page 10225 Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint. 3. Support the lower control arm with a floor stand as far outboard as possible and raise suspension to just below the ride height. 4. Install the J 8001 or a suitable dial indicator in a way to measure the vertical lash in ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 5. Gently lift or pry the suspension to induce the ball joint movement. 6. If the dial indicator reading is more than 1.524 mm (0.060 in), replace the lower ball joint. Page 14433 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat cushion bracket mounting nuts (2). 4. Remove the rear seat cushion bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the rear seat cushion bracket to the seat cushion bottom with the four mounting nuts (2). Tighten the rear seat cushion bracket mounting nuts to 25 N.m (18 lb ft). 2. Install the rear seat bracket trim covers (1). 3. Install the seat in the vehicle. Seat Cushion Latch Release Assembly Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Latch Release Assembly Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). 4. Remove the 3 bolts securing the rear seat cushion latch to the seat pan. Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement - Front (Chevrolet (X88) ONLY) Removal Procedure 1. Remove the grille 2. Remove the front fascia. 3. Remove the front impact bar. 4. Place the impact bar on a clean, prepared surface. 5. Remove the bolt that retains the tow hook to the impact bar. 6. Remove the tow hook from the impact bar. Installation Procedure 1. Install the tow hook to the impact bar, ensuring that the locating pin is properly indexed to the impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt which retains the tow hook to the impact bar. Tighten the bolt to 50 N.m (37 lb ft). 3. Install the impact bar. 4. Install the fascia. 5. Install the grille. Page 13160 bulkhead. 3. Install the cable to the release handle (3). 4. Seat the cable grommet (1) to the bulkhead. 5. Install the release handle (3) to the left side cowl panel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the nut (2) that retains the release handle (3) to the left side cowl panel. Tighten the nut to 7 N.m (62 lb in). 7. Route the cable as previously noted, over the battery tray, between the headlamp panel assembly and the radiator. 8. Attach the cable to the retainers on the wheelhouse and the hood hold open rod bracket. 9. Install the cable to the hood latch assembly. 10. Install the hood latch. 11. Install the front grille. 12. Install the left closeout/insulator panel. 13. Install the left front door sill panel. Page 12526 Page 2225 Conversion - English/Metric Page 1925 For vehicles repaired under warranty, use the table. Disclaimer Recall 01V334000: Transfer Case Control Module Update PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 6751 Page 1988 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 15478 Equivalents - Decimal And Metric Part 1 Page 1883 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Locations Locations View Page 10299 1. Install the rear axle tie rod to the vehicle. 2. Install the rear axle tie rod to frame mounting bolt and nut. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle tie rod to the axle mounting bolt and nut. Tighten the rear axle tie rod mounting bolts to 195 Nm (144 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 927 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Procedures Carpet: Procedures Carpet Replacement - Front REMOVAL PROCEDURE 1. Remove the front bucket seats. 2. Remove the front door sill plates. 3. Remove the center pillar trim panels. 4. Remove the floor console. 5. Remove the floor console bracket. 6. Remove the carpet from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. 2. Feed the front edge of the carpet underneath the instrument panel. 3. Align the holes in the carpet to the seat studs on the floor panel. 4. Position the rear carpet over the edge of the front carpet. 5. Install the floor console bracket. 6. Install the floor console 7. Install the center pillar trim panels. 8. Install the front door sill plates. 9. Install the front bucket seats. Page 2638 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the block base retaining nuts to the floor studs. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 905 For vehicles repaired under warranty, use the table. Disclaimer Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 4275 Electrical Symbols Part 3 Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Fog Lamp Relay Replacement (RPO T96) Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T96) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood junction block. 3. Use the J 43244 in order to remove the fog lamp relay (1) from the underhood junction block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the fog lamp relay (1) to the underhood junction block. 2. Install the protective covers to the underhood junction block. 3. Close the hood. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes A/T - Key Will Not Release From Ignition Lock Cylinder Automatic Transmission Shift Boot: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 6261 Electronic Brake Control Module (EBCM) C1 Page 9590 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove the shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 15. Lift the console, disconnect the wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (TrailBlazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Light Blue wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Yellow wire. Page 12864 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 13034 Page 4546 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. Page 15984 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 7655 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 13051 Page 12044 Electrical Symbols Part 5 Page 5054 Various symbols are used in order to describe different service operations. Page 13502 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 8816 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 6478 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 2800 Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 1. Install the wheel and the tire assembly. Align the locating mark of the tire and wheel to the hub assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel nuts hand tight. Tighten the nuts evenly and alternately to avoid excessive runout. Tighten the wheel nuts to 140 Nm (103 ft. lbs.) using J39544-KIT./ 3. Install the wheel hub cap, if equipped. 4. Lower the vehicle. Page 12423 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 14783 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 1517 Electrical Symbols Part 8 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 4143 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11783 Page 13579 ^ The center pillar harness clips (1) ^ The center pillar harness clips (3) ^ The center pillar harness clips (4) NOTE: Refer to Fastener Notice in Service Precautions. 22. Install the ground terminals and the ground bolt (2) to the center pillar. Tighten Tighten the bolt to 10 N.m (88 lb in). 23. If equipped with OnStar(R) perform the following procedure: 23.1. Install the navigation antenna cable to the right center pillar. 23.2. Install the navigation antenna cable to the right side door sill attachments. 23.3. Install the navigation antenna cable to the communication interface module. 24. Install the sunshades to the headliner. 25. If equipped, install the front and rear overhead console. 26. Install the video display. 27. Attach the mechanic's wire to the end of the headliner harness positioned behind the IP. 28. Pull the bottom of the mechanic's wire away from the cowl insulation access hole in order to position the headliner harness behind the IP. 29. Attach the 3 clips (1) securing the wire harness to the windshield pillar. 30. Attach the lower rosebud (2) retaining the headliner harness to the cowl. 31. Connect the coax cable (2) and headliner harness connector (1). 32. Close the IP compartment door. 33. Install the right sound insulator. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Locations Locations View Page 14308 5. Install the inboard/outboard rear seat back cushion hinge covers with the three screws. Tighten Tighten the seat back cushion hinge cover screws to 2 N.m (18 lb in). Page 5739 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11964 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 6507 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Page 66 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 14438 3. Remove the pull handle assembly (1). 4. Remove the J-strips (2) securing the rear seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. 6. Remove the hog rings (1) from the seat cover. 7. Carefully separate the hook and loop fastener strips (2) holding the cover to the pad. 8. Remove the hog rings (1). Installation Procedure 1. Install the hog rings (1) securing the seat cover to the pad. 2. Pull the cover over the pad pressing the hook and loop fastener strips (2) together. 3. Install the cover flaps to the pad with hog rings (1). Page 11306 1. Install the SDM to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the SDM to the floor panel. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Connect the electrical connectors (2) to the SDM (1). 4. Return the carpet to the fully installed position. 5. Install the console mounting bracket to the floor panel. 6. Install the floor console. 7. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 7927 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 12517 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 11176 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch - HVAC Systems Manual A/C Low Pressure Switch - HVAC Systems Automatic Page 3091 Oil Filter: Technical Service Bulletins Engine - Oil Filter Usage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-026 Date: November, 2001 INFORMATION Subject: Oil Filter Usage Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) The correct oil filter to be used for replacement is the AC Delco PF-58. The correct part number for the filter is P/N 25014377 (in Canada, use P/N 729865). New vehicles may have a different filter installed from the factory. Use only the AC Delco PF-58 when changing the filter. Parts are currently available from GMSPO. DISCLAIMER Page 8969 10. Remove the brake caliper mounting bracket. 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. Page 14940 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9912 For vehicles repaired under warranty, use the table. Disclaimer Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement Trailblazer, Envoy, and Bravada TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor suction/discharge hose nut (3). 3. Remove the compressor suction/discharge hose from the compressor (4). 4. Remove the sealing washers. 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the O-ring seals. 12. Cap or plug all of the open connections. INSTALLATION PROCEDURE Page 12819 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1311 Electrical Symbols Part 6 Page 1201 Engine Oil Pressure (EOP) Switch Page 514 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 11251 8. Install and secure the headlamp wire harness in the retaining clip (1). 9. Install the grille. 10. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 16004 Equivalents - Decimal And Metric Part 2 Arrows and Symbols A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 10970 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement - Auxiliary 2. Remove the screws from heater core cover-auxiliary (3) from the HVAC module-auxiliary. 3. Remove the heater core cover-auxiliary (3). 4. Remove the HVAC module pass thru seal-auxiliary. Remove the heater core-auxiliary (2) from the HVAC module-auxiliary. INSTALLATION PROCEDURE Page 6180 Capacity Specifications Coolant: Capacity Specifications Cooling System 13.9 qt (US) Page 9044 Parking Brake Cable: Service and Repair Enabling the Park Brake Cable Automatic Adjuster Enabling the Park Brake Cable Automatic Adjuster 1. Lower the park brake lever. 2. Raise the park brake lever. 3. Lift the park brake lever boot to gain access to the multiplier lever at the front of the park brake lever assembly. 4. Pivot the multiplier lever up and down 3 times. 5. Cycle the park brake lever up and down three times for auto adjustment. 6. Lower the park brake lever boot. Page 10271 3. Remove the outer tie rod retaining nut. 4. Disconnect the outer tie rod from the steering knuckle using J24319-B. 5. Remove the stabilizer shaft link lower retaining nut. 6. Disconnect the stabilizer shaft link and washer from the lower control arm. Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6051 Crankshaft Position (CKP) Sensor Page 3946 Electrical Symbols Part 3 Page 11451 26. Remove the seat belt upper bracket and retractor assembly from the seat. 27. Install the new seat belt retractor and original bracket on the seat back frame. 28. Apply threadlocker to the upper retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 29. Install the push-in fastener to attach the retractor to the seat back frame. 30. Apply threadlocker to the lower retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 31. Install the seat belt webbing material into the slot in the upper bracket. 32. Install the seat back panel and four push-in fasteners. 33. Reposition the pad and cover. 34. If equipped, connect the seat back heating element electrical connector. 35. Position the seat back cover over the top of the seat back and begin pulling it down over the seat back. 36. Position and install the seat back cover around the side impact air bag module. 37. Install the head restraint retainers. 38. Install the head restraint. 39. Install the push pins that secure the bottom of the seat back cover to the seat back frame. 40. Connect the J-strip at the bottom of the seat cover. 41. Install the seat belt bezel to the seat belt material, position on the top of the seat back and install the attaching screw. Tighten Tighten the screw to 6 Nm (53 lb in). 42. Install the seat belt anchor and nut to the seat adjuster. Tighten Tighten the nut to 52 Nm (38 lb ft). 43. Install the outer trim panel to the side of the seat cushion and install the screws. Tighten Page 13175 Disclaimer Page 11599 6. Remove the antenna mast. 7. Open the hood. 8. Remove the radio antenna cable assembly retaining screws. 9. Pass the antenna cable and grommet assembly through the fender opening. 10. Remove the radio antenna cable assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the radio antenna cable assembly to the vehicle. 2. Pass the antenna cable and grommet assembly through the fender opening. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the radio antenna cable assembly retaining screws. Tighten Tighten the radio antenna cable assembly screws to 2.8 N.m (25 lb in). 4. Close the hood. 5. Install the antenna mast. Electrical - Proper Jump Starting Procedure Jump Starting: Technical Service Bulletins Electrical - Proper Jump Starting Procedure Bulletin No.: 04-06-03-005A Date: May 17, 2006 INFORMATION Subject: Proper Connection Information to Avoid Blown 125 Amp Fuse and Various Interior Electrical System Conditions When Jump Starting Vehicle Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2007 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-06-03-005 (Section 06 - Engine/Propulsion System). It has been found that some dealers may be using the IP battery positive stud at the underhood fuse block to jump start the vehicle. This bulletin is being issued to inform dealers that investigation has indicated the 125 amp mega fuse (no. 48) located in the engine compartment fuse block may be blown resulting in various electrical system conditions due to using this improper connection. To properly jump start the vehicle, you must always use the following connections. For the positive connection, use the battery terminal. For the negative connection, use the remote terminal located on the front engine lift bracket (marked "GND"). Page 11326 Child Seat Tether Attachment: Service and Repair Child Restraint Tether Anchor Trailblazer, Envoy, Bravada CHILD RESTRAINT TETHER ANCHOR REPLACEMENT - REAR NO.1 REMOVAL PROCEDURE 1. Open the liftgate. 2. Remove the bolt that retains the child restraint tether anchor to the floor panel. 3. Remove the child restraint tether anchor from the floor panel. INSTALLATION PROCEDURE 1. Install the child restraint tether anchor to the floor with the pivot point of the anchor ring indexed toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. install the bolt that retains the child restraint tether anchor to the floor panel. Tighten Tighten the child restraint tether anchor bolt to 35 N.m (26 lb ft). 3. Close the liftgate. Trailblazer EXT, Envoy XL Page 11675 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Locations Locations View Page 4922 Body Control Module: Description and Operation The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the Driver Door Module (DDM), Passenger Door Module (PDM) and the Liftgate Module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Specifications Coolant Reservoir: Specifications Coolant Recovery Reservoir Bolt 106 1b in Coolant Recovery Reservoir Nut 88 inch lbs. Page 9897 27. Remove the CPA from the rear audio control connector and remove the eight wires from the designated cavities of the rear audio control in-line harness connector and replace them with the wires from the new harness as listed below. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. Also, this wiring harness has two Dark Blue and two Brown wires. It may be necessary to cut a small portion of the electrical tape wrap to determine which wires are paired. ^ Pair One - Remove wire in cavity B3 and insert the Brown/White wire. - Remove wire in cavity A8 and insert the Brown wire. ^ Pair Two - Remove wire in cavity A9 and insert the Dark Blue wire. - Remove wire in cavity A1 and insert the Black wire. ^ Pair Three - Remove wire in cavity B1 and insert the Brown wire. - Remove wire in cavity B5 and insert the Yellow wire. ^ Pair Four - Remove wire in cavity B6 and insert the Light Blue wire. - Remove wire in cavity B2 and insert the Dark Blue wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires as close to the taped portion of the original harness as possible. 28. Lift the carpet in the left rear door area, and slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 29. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 30. Route the new harness under the carpet from the rear of the console to the 8-way connector. 31. Remove the eight wires from the 8-way inline harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. ^ Remove wire in cavity A and insert the Gray wire. ^ Remove wire in cavity B and insert the Tan wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Light Green wire. ^ Remove wire in cavity E and insert the Yellow wire. ^ Remove wire in cavity F and insert the Brown wire. ^ Remove wire in cavity G and insert the Light Blue wire. ^ Remove wire in cavity H and insert the Dark Blue wire. ^ Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. Page 3965 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 4434 Fuel System Diagnosis - Steps 12-17 Page 2986 1. Lubricate and fill the valve lash adjusters with engine oil. 2. Install the valve lash adjusters in their original locations. 3. Lubricate the valve rocker arm roller. 4. Install the valve rocker arms in their original locations. 5. Coat the camshaft journals with engine oil. 6. Install the camshafts to their original position Page 3980 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 9042 13. Install the park brake cables to the retainer. 14. Install the park brake cables to the park brake equalizer. 15. Install the rear propeller shaft. 16. Lower the vehicle. Refer to Vehicle Lifting. 17. Enable the park brake automatic adjuster. 18. Test the park brake operation. 19. Adjust the park brake cables. Page 1510 Electrical Symbols Part 1 Page 15370 Equivalents - Decimal And Metric Part 1 Page 1956 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 9803 C500 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 13088 For 2007 vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Page 12562 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 15597 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 4082 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8448 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 10038 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 14761 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8897 12. Remove the brake pad retaining clip from the brake caliper. 13. Remove all foreign material from the brake caliper using denatured alcohol. Installation Procedure Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips. 1. Install the brake pad retaining clips to the brake caliper mounting bracket. 2. Install the brake pad retaining clip to the brake caliper. Page 14773 Electrical Symbols Part 2 Page 14230 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 1034 Trailblazer, Envoy, Bravada Navigation Module: Service and Repair Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the right rear seat cushion. 2. Remove the communication interface module. 3. Using a flat bladed tool, release the retaining tab on the upper bracket. 4. Slide the upper bracket inboard until the retaining tabs are released from the processor bracket. 5. Remove the upper bracket from the processor bracket. 6. Remove the nut that retains the processor bracket to the rear seat back stud. 7. Remove the processor bracket from the vehicle. INSTALLATION PROCEDURE Page 4063 Electrical Symbols Part 4 Page 1180 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 9725 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 5171 Conversion - English/Metric Page 11184 Ambient Light/Sunload Sensor Assembly Page 3215 Electrical Symbols Part 4 Page 6418 Page 4743 Fuel Tank Pressure (FTP) Sensor Page 12182 Speaker: Service and Repair Speaker Replacement - Front Upper REMOVAL PROCEDURE 1. Remove the trim pad. IMPORTANT: Ensure that the speaker electrical connector does not fall into the speaker opening. 2. Remove the 3 screws that retain the speaker to the instrument panel (IP) substrate. 3. Disconnect the speaker electrical connector. 4. Remove the speaker from the IP. INSTALLATION PROCEDURE Page 8317 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Page 1404 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 8274 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 140 Page 13748 Door Lock Actuator - Front Passenger Door Lock Actuator - Liftgate Side Impact Sensor Impact Sensor: Diagrams Side Impact Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Page 11055 Refrigerant Oil: Technical Service Bulletins A/C - Revised Compressor Oil Balancing Procedure File In Section: 01 - HVAC Bulletin No.: 02-01-38-006 Date: December, 2002 SERVICE MANUAL UPDATE Subject: Revised Compressor Oil Balancing Procedure Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada This bulletin is being issued to revise the Compressor Oil Balancing Procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Draining Procedure Important: Drain and measure as much of the refrigerant oil as possible from the removed compressor. 1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean, graduated container. Rotate the compressor shaft to assist in draining the compressor. 2. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor. 3. Properly discard the used refrigerant oil. Page 9232 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 9229 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8570 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10491 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 10567 Disclaimer Page 2921 For vehicles repaired under warranty, use the table. Disclaimer Page 5801 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 610 Page 14729 DISCLAIMER Restraints - Seat Belt Retractor Jamming Prevention Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Retractor Jamming Prevention Bulletin No.: 03-09-40-006B Date: December 02, 2005 INFORMATION Subject: Information on Avoiding Front Seat Belt Retractor Jamming When Storing Seat Belt Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and Saab 9-7X models. Please discard Corporate Bulletin Number 03-09-40-006A (Section 09 - Restraints). This bulletin is being issued to provide information to the customers if they comment that the left or right front seat belt may appear to not release from the retractor when trying to put on the seat belt. A Description For Your Customer This condition generally does not require replacement of any parts. This condition is the result of allowing the belt to enter the retractor at a high rate of speed. If the belt is allowed to go all the way back into the retractor very quickly, it is possible that the force of the belt stopping suddenly against the seat back will vibrate the retractor. This vibration "fools" the retractor into thinking that the vehicle is changing velocity. The normal function of the retractor under this condition is to lock the belt. How to Correct or Eliminate the Condition The only way to completely eliminate the condition is not to allow the belt to retract back all the way into the retractor quickly. The fast retraction usually occurs when the customer holds the latch while unbuckling and guides the webbing into the retractor quickly until it's fully stowed. As long as the customer guides the belt at a slower rate of speed, the retractor will work consistently without locking. Also, if the customer unbuckles the belt and lets the webbing retract on its own (without guiding it), there is generally enough friction from the belt against clothing to slow down the belt so it won't lock when it fully stows. If the customer does allow the belt and latch plate to retract quickly, the retractor can easily be restored to normal operation. Simply pull on the belt to create some slack in the webbing and pay back some of the webbing into the retractor. Slack can also be created by pushing on the foam at the top of the seat back. After a maximum of 10 mm (0.39 in) of webbing is introduced into the retractor, it will unlock and function again. Please demonstrate this action to your customer. After an explanation and demonstration, most customers should be able to unlock the retractor without a problem. You may give a copy of this bulletin to your customer for further reference. Disclaimer Page 10230 1. Install the upper ball joint to steering knuckle using J9519-E, J21474-01, and J45117. 2. Install the upper ball joint retaining clip. 3. Install the steering knuckle with wheel hub attached. 4. Install the tire and wheel. 5. Lower the vehicle. 6. Check the front wheel alignment. Page 3409 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 13577 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner and install the left inboard sunshade retaining clip (5). Refer to Coupling Replacement Antenna Inner and Coupling Replacement - Antenna Outer. 4. Install the right rear push pin (2) 5. Install the left rear push pin (3). 6. Install the assist handles to the roof panel. 7. Connect the electrical connector to the cellular phone antenna. 8. Connect the radio control module electrical connector to the right body side window. 9. Install the coat hooks to the roof panel. 10. Connect the radio antenna module electrical connector to the left body side window. 11. Install the upper rear quarter trim panels. 12. Connect the navigation antenna electrical connector, if equipped. 13. Connect the rain sensor electrical connector, if equipped. 14. Connect the inside rear view mirror electrical connector (6). 15. If the vehicle is NOT equipped with a sunroof, seat the 2 interlocking strips (1). Page 9769 C201 Part 3 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 12737 Body Control Module: Description and Operation The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the Driver Door Module (DDM), Passenger Door Module (PDM) and the Liftgate Module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 565 Page 431 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Locations Locations View Page 11689 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 8303 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 2232 5. With the aid of an assistant, remove the quarter window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Connect the antenna lead located on the rear quarter window, if equipped. 3. Install the upper quarter trim. 4. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 5. Inspect the radio or the OnStar(R) system, if equipped, to verify reception. 6. Close the liftgate window. Page 12898 10. Place the hinge (1) into position and hand tighten the two attaching bolts. 11. Remove the feed wire from the hinge. 12. Install and hand tighten the two remaining bolts. 13. Align the hinge to the original scribe location and torque all four bolts to 25 N.m (18 ft.lb). 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). Page 1325 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Locations Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 15327 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 13323 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Page 10624 Locations View - HVAC Systems - Automatic Page 1671 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 11716 Page 5153 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 12432 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 12668 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15416 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4474 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 14881 Miniwedge (Door Jamb Switch) - Liftgate Page 4930 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. Page 109 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 10700 Ambient Temperature Sensor / Switch HVAC: Locations Locations View - HVAC Systems - Automatic Page 4155 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 10947 Installation Procedure Important: Install the shorter screen end of the expansion tube into the evaporator tube first. 1. Install the expansion tube (4) to the evaporator tube (1). 2. Use the J 26549-E in order to install the expansion tube (4). 3. Install the new O-ring seal. 4. Assemble the evaporator tube at the block fitting (1). 5. Install the nut (2) to the evaporator tube block (3). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the evaporator tube nut. Tighten Tighten the nut to 28 N.m (21 lb ft). 7. Install the evaporator tube to the evaporator. 8. Install the evaporator tube nut (5) to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 9. Install the coolant reservoir. 10. Install the accumulator. 11. Recharge the refrigerant system. 12. Leak test the fittings of the components using the J 39400-A. Page 5944 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Specifications Refrigerant System Capacities Page 13635 3. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 4. Index the locating tabs on the trim panel to the holes in the body. 5. Connect the wiring harness connector to the auxiliary power outlet. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the five screws that the retain the rear quarter trim panel to the body. Tighten Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 7. Install the seat belt lower anchor. Tighten Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 8. Install the left rear door sill panel. 9. Install the liftgate sill plate. 10. Install the left body side window forward garnish molding. 11. Install the left body side window rear garnish molding. 12. Return the third row seats to the upright position. 13. Install the cargo shelf. Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the cargo shade/cover. 2. Remove the inflator access panel. 3. Remove the right rear quarter upper trim panel. 4. Remove the liftgate sill plate. 5. Remove the right rear door sill panel. 6. Remove the lower seat belt anchor bolt. 7. Release the retaining clips that retain the trim panel to the body. Page 4126 Oxygen Sensor: Locations Locations View Page 14990 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5146 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 8351 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 6023 Electrical Symbols Part 7 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Transfer Case Shift Control Module C1 Page 5581 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 1807 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1120 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 3135 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Body - Liftgate Glass Hard to Close Trunk / Liftgate Handle: All Technical Service Bulletins Body - Liftgate Glass Hard to Close File In Section: 08 - Body and Accessories Bulletin No.: 03-08-66-006 Date: June, 2003 TECHNICAL Subject: Lift Gate Glass Hard to Close (Replace Weatherstrip and Shim Handle) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the lift gate glass is hard to close. Cause The weatherstrip may be too stiff and the glass bounces back when closing. Correction Replace the weatherstrip and shim the lift gate window handle. 1. Remove the garnish molding from the lift gate for easy access to the weatherstrip. 2. Remove the lift gate weatherstrip. 3. Install the lift gate glass weatherstrip. 4. Install the garnish molding. 5. Loosen the two nuts that retain the handle and the striker to the glass and install the shim between the glass and the striker. Tighten Tighten the nuts to 6 N.m (53 lb in). Important: Service and Repair Parking Light Bulb: Service and Repair PARK/TURN SIGNAL/SIDE MARKER LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the headlamp. 3. Rotate the bulb and socket counter-clockwise in order to remove the bulb and socket from the housing. 4. Remove the side marker bulb (4) or turn signal/park bulb (3) from the socket. INSTALLATION PROCEDURE 1. Install the side marker bulb (4) or turn signal/park bulb (3) to the socket. 2. Wipe the bulb with a clean cloth to ensure the bulb is free of any dirt or oil. 3. Install the bulb and socket to the headlamp by rotating the bulb and socket clockwise, locking the retaining tabs to the headlamp. 4. Install the headlamp. 5. Close the hood. Page 11050 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft) 4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 5. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 6. Install the air cleaner. Service and Repair Parking Lamp Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the park lamp relay (1) from the bussed electrical center. INSTALLATION PROCEDURE Page 3104 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 4325 Electrical Symbols Part 7 Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 6010 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 12317 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 8807 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 6944 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Service and Repair Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the harness connector (2) from the evaporative emission (EVAP) canister purge valve (1). 3. Disconnect the EVAP purge pipe from the EVAP canister purge valve. 4. Disconnect the engine vacuum pipe from the EVAP canister purge valve. 5. Remove the purge valve (2) from the purge valve mounting bracket. 6. If replacing the purge valve bracket, remove the attaching bolt (1) and purge valve bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 9478 C201 Part 1 Page 6407 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 5029 Electrical Symbols Part 8 Page 14307 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the seat back cushion mounting bolts (2) securing the rear seat back frame to the inboard/outboard rear seat back cushion hinge assembly. Tighten Tighten all rear seat back cushion mounting bolts to 25 N.m (18 lb ft). 2. Install the rear center seat belt retractor assembly, if you are replacing the frame from the left-hand rear seat. 3. Install the seat back panel to the frame with push pins (1). 4. Install the seat back cover and pad to the seat back. Procedures Door Lock Cylinder: Procedures LOCK CYLINDER REPLACEMENT - DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector from the door. 3. Remove the outside handle from the door. 4. Remove the lock cylinder from the door handle. INSTALLATION PROCEDURE 1. Install the lock cylinder to the door handle. 2. Install the outside handle to the door. 3. Install the water deflector to the door. 4. Install the door trim panel to the door. Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 787 Electrical Symbols Part 1 Page 1516 Electrical Symbols Part 7 Page 12684 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 936 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 7146 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ..................................................................... 48-54 psi KOEO Key On Engine Off Page 4350 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8598 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4401 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 2286 Fuel Pressure: Testing and Inspection SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Fuel System Diagnosis - Steps 1-3 Page 275 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 9212 Electrical Symbols Part 7 Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15760 Electrical Symbols Part 2 Page 15888 Electrical Symbols Part 3 Page 7412 17. Align the swage clamp (2) within J41048. 18. Place the top half of the J410480n the bottom half. 19. Check to make sure there are no pinch points on the seal before proceeding with procedures. 20. Insert the bolts (2). Tighten the bolts (2) by hand until snug. Notice: Refer to Fastener Notice in Service Precautions. 21. Align the following items: ^ The seal ^ The halfshaft bar ^ The swage clamp ^ Tighten each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 22. Loosen the bolts. 23. Separate the dies. 24. Check the swage clamp for any "lip" deformities. If the deformities exist, place the swage clamp back into the J4104B. Important: Ensure that the retaining ring side of the CV joint inner race faces the halfshaft bar (1) before installation. 25. Place the retaining snap ring into the CV joint inner race. Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the 2HI position. 1. Raise the vehicle. 2. Remove the fuel tank shield, if equipped. 3. Disconnect the motor/encoder electrical connector (1). 4. Remove the motor/encoder mounting bolts. Page 8381 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 11793 Page 7293 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Body - Liftgate Glass Binds/Won't Open Fully Center Mounted Brake Lamp: All Technical Service Bulletins Body - Liftgate Glass Binds/Won't Open Fully Bulletin No.: 04-08-66-017 Date: November 09, 2004 TECHNICAL Subject: Liftgate or Liftgate Glass Binds, Does Not Open Completely, CHMSL Hits Roof (Remove Material from CHMSL Applique) Models: 2002-2005 Chevrolet TrailBlazer EXT 2002-2005 GMC Envoy XL Condition Some customers may comment that the liftgate or liftgate glass binds when opening or does not open all the way. Cause This condition is caused by the Center High Mounted Stop Lamp (CHMSL) applique hitting the roof of the vehicle. Correction Verify that the CHMSL applique is not loose or broken off one or more of its mounting points. If the applique is broken, it will be necessary to order a replacement part. Important: ^ It should not be necessary to replace the liftgate glass. ^ All measurements and alterations should take place prior to paint finish. ^ It is necessary to install any replacement parts in order to measure to determine if further modification is required. To achieve the proper clearance, modification to the applique is required using the following procedure: 1. Measure (with applique installed) the area of interference in order to determine the material to be removed. ^ The top surface (height) of the applique should line up approximately 1 mm (0.039 in) below the top surface of the roof. ^ A gap of 6-8 mm (0.236-0.315 in) should exist between the roof and the applique to allow for adequate clearance while opening the liftgate. Page 2612 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 15312 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 13367 3. Install the bellcrank rod to the outside door release handle. 4. Install the liftgate trim panel. 5. Install the license pocket lamps. Page 14789 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12082 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitters). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(TM) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. NON-COMPATIBLE GARAGE DOOR OPENERS Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Locations Locations View Page 9693 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Body - Revised Liftgate Lock Cylinder Replacement Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Body - Revised Liftgate Lock Cylinder Replacement Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X This bulletin is being issued to revise the Lock Cylinder Replacement - Liftgate procedure in the Body Rear End sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. Refer to Wiper Motor Replacement - Rear. 2. Remove the lock rod from the lock cylinder. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 1761 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13362 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 8837 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9509 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 11800 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 3236 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14184 2. Verify that the retaining clips are fully seated. 3. Install the rear seat head restraint posts to the head restraint retractor, verifying that the notches in the head restraint posts are indexed toward the back of the seat. 4. Lower the head restraint to the full down position. Head Restraint Guide Replacement - Rear No. 1 Head Restraint Guide Replacement - Rear No. 1 Removal Procedure 1. Remove the head restraint. 2. Remove the seat back cover and pad high enough to expose the head restraint guides. 3. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. Installation Procedure 1. Install the head restraint guides by pushing the guides into the frame until the retaining tabs (1) lock the guide in place. 2. Install the seat back cover and pad to the seat back. 3. Install the head restraint. Head Restraint Retractor Assembly Replacement - Rear No. 1 Head Restraint Retractor Assembly Replacement - Rear No. 1 Removal Procedure Caution: Refer to Prevent Accidental Deployment of the Head Restraint Retractor Assembly in Service Precautions. 1. Remove the seat back cover and pad. Page 15596 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 3239 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 4818 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 12461 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Diagrams Seat Belt Switch - Driver Page 9116 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 4024 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 10268 Important: Ensure that the lower control arm is parallel to the lower control arm bracket during the installation and tightening of the lower control arm mounting bolts and nuts. This will ensure correct alignment of the lower control arm bushings. 5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten the nuts to 110 Nm (81 ft. lbs.). Important: There is a washer between the stabilizer shaft link and the lower control arm made of herded steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. 6. Install the stabilizer shaft link and washer to the lower control arm. 7. Install the stabilizer shaft link retaining nut. Tighten the nut to 100 Nm (74 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Check the front wheel alignment. Upper Control Arm Replacement Upper Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the upper ball joint to upper control arm pinch bolt and nut. 4. Disconnect the upper control arm from the steering knuckle. Procedures License Plate Bracket: Procedures LICENSE PLATE POCKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the license pocket lamps. 2. Remove the liftgate trim panel. 3. Disconnect the bellcrank rod from the outside door release handle. 4. Remove the screws that retain the license pocket to the liftgate. 5. Remove the license pocket from the liftgate. INSTALLATION PROCEDURE Diagrams Turn Signal Switch: Diagrams Turn Signal/Multifunction Switch C1 Part 1 Turn Signal/Multifunction Switch C1 Part 2 Page 10497 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 13361 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 11426 26. Remove the seat belt upper bracket and retractor assembly from the seat. 27. Install the new seat belt retractor and original bracket on the seat back frame. 28. Apply threadlocker to the upper retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 29. Install the push-in fastener to attach the retractor to the seat back frame. 30. Apply threadlocker to the lower retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 31. Install the seat belt webbing material into the slot in the upper bracket. 32. Install the seat back panel and four push-in fasteners. 33. Reposition the pad and cover. 34. If equipped, connect the seat back heating element electrical connector. 35. Position the seat back cover over the top of the seat back and begin pulling it down over the seat back. 36. Position and install the seat back cover around the side impact air bag module. 37. Install the head restraint retainers. 38. Install the head restraint. 39. Install the push pins that secure the bottom of the seat back cover to the seat back frame. 40. Connect the J-strip at the bottom of the seat cover. 41. Install the seat belt bezel to the seat belt material, position on the top of the seat back and install the attaching screw. Tighten Tighten the screw to 6 Nm (53 lb in). 42. Install the seat belt anchor and nut to the seat adjuster. Tighten Tighten the nut to 52 Nm (38 lb ft). 43. Install the outer trim panel to the side of the seat cushion and install the screws. Tighten Page 15998 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 14387 1. Remove the seat back from the vehicle. 2. Remove the seat belt buckle bracket, on the right side only. 3. Remove the seat belt anchor bolt from the bracket. 4. Release the seat belt bezel from the seat back by pressing in the buttons (1) on the plastic retainers. 5. Remove the seat belt bezel by sliding it off the seat belt. 6. Remove the head restraints. Page 4996 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Page 5995 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Locations Information Bus: Locations Locations View Page 4141 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 11917 Page 15510 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 12691 Various symbols are used in order to describe different service operations. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 14680 Rear Door Window Glass Weatherstrip: Service and Repair Window Weatherstrip Run Channel Assembly Replacement - Rear Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. Page 5223 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 16083 Turn Signal/Multifunction Switch C2 Turn Signal/Multifunction Switch C3 Page 10748 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 15236 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 108 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 5035 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 10471 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 1414 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5951 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 2429 IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to 10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater corn hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Trailblazer EXT, and Envoy XL TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE Page 14395 9. Release the hook and loop fasteners (2, 3) securing the cover to the pad. 10. Remove the three hog rings (1) securing the cover to the pad. 11. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. 12. Remove the seat back cover and pad. The pad may be glued to the frame in places from the initial set assembly process. INSTALLATION PROCEDURE Page 14172 1. Remove the front seat assembly. 2. Remove the front seat head restraint. 3. Pull the seat back cover and the seat back pad up high enough to expose the head restraint guides. Refer to Seat Back Cover and Pad Replacement - Front. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the guides from the seat frame. 5. Remove the guides from the seat back frame. INSTALLATION PROCEDURE 1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the frame. Page 3306 DISCLAIMER Page 14646 4. Install the front door sill plate. Page 15238 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 549 Control Module HVAC: Diagrams HVAC Systems - Automatic Blower Motor Control Module Blower Motor Control Processor - Auxiliary Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5076 Electrical Symbols Part 2 Page 8449 11. Using J2845fl release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 5474 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 14007 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 5936 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9456 C101 Part 2 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes C104 Part 1 Page 7586 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 4250 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 4088 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 3884 Engine Control Module: Service and Repair Powertrain Control Module Programming and Setup BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel - Interior lights - Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. - Heating, ventilation, and air conditioning (HVAC) systems - Engine Cooling fans etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. Do NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. - All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2(TM) to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2(TM), select Service Programming. 6. Identify vehicle information as requested by the Tech 2(TM) 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline(TM) terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2(TM) and disconnect the Tech 2(TM) from the vehicle 12. Turn OFF the ignition. 13. Connect the Tech 2(TM) to the Techline(TM) terminal. 14. Select Service Programming. 15. Select Tech 2(TM) as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. - Normal-This type of programming is for updating an existing calibration or programming a new controller. - Vehicle configuration Index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline(TM) terminal. Observe, you will need to contact the Techline(TM) Customer Support center to use this option. - Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2(TM). 23. After the download is complete, turn OFF the Tech 2(TM). 24. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 25. Install the Tech 2(TM) to the data link connector (DLC). 26. Turn ON the Tech 2(TM). 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Diagrams Engine Oil Level And Temperature Sensor Page 4594 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Sunroof Glass Panel Replacement Sunroof / Moonroof Panel: Service and Repair Sunroof Glass Panel Replacement REMOVAL PROCEDURE IMPORTANT: The sunroof must be in the fully closed position prior to removing the glass panel. 1. Open the sunshade panel. 2. Remove the 4 screws (2) that retain the glass panel (1) to the sunroof assembly. 3. Remove the glass panel from the top of the vehicle. INSTALLATION PROCEDURE 1. Position the glass panel (1) to the vehicle. 2. Install the screws (2) that retain the glass panel (1) to the sunroof assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Adjust the glass panel height so that the glass is flush with the roof panel. Tighten Tighten the screws to 3 N.m (27 lb in). Page 5784 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 5473 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5990 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 13714 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 9998 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 6758 For vehicles repaired under warranty, use the table. Disclaimer Page 2468 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 868 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Specifications Exhaust Pipe: Specifications Exhaust Pipe Bolts 37 ft. lbs. Exhaust Pipe Clamp Nuts 37 ft. lbs. Exhaust Pipe to Manifold Nuts 37 ft. lbs. Page 1618 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 3188 Oil Pick Up/Strainer: Specifications Oil Pump Pickup Tube 89 inch lbs. Page 7981 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 7948 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 5243 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 754 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1459 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 13700 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Master Cylinder Bench Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 GM U.S. P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 4557 Electrical Symbols Part 4 Page 11694 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 10627 Locations View Page 5582 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 1760 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2199 Electrical Symbols Part 8 Liftgate - License Plate Housing Paint Rubs Through License Plate Frame: Customer Interest Liftgate - License Plate Housing Paint Rubs Through File In Section: 08 - Body and Accessories Bulletin No.: 02-08-66-004 Date: April, 2002 TECHNICAL Subject: Paint Rub Through on Liftgate Around Edge of License Plate Housing/Pocket (Install Insulating Seal/Gasket) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the paint on the liftgate around the edges of the license plate housing or pocket appears to be rubbing through or wearing off. Cause Changes in temperature may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing comes in contact with or rubs against the paint surface on the liftgate. Correction Remove the license plate housing from the liftgate. Refer to the License Plate Pocket Replacement procedure in the Service Manual (SI2000 Document ID # 740995). Install an insulating perimeter seal or gasket on the backside edge of the housing as shown. When properly installed, the seal (1) will start at one side of the liftgate release handle (2) and go completely around the housing stopping at the other side of the handle. Do NOT attempt to install the seal on the liftgate housing directly below the release handle. Once installed, it may be necessary to trim off any excess seal material. Parts Information Parts are expected to be available 4-22-2002 from GMSPO. Warranty Information Page 12254 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 12043 Electrical Symbols Part 4 Page 818 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8194 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4177 Electrical Symbols Part 3 Page 4180 Electrical Symbols Part 6 Page 6970 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Page 7352 Disclaimer Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Electrical - Intermittent Interior Electrical Concerns Control Assembly: Customer Interest Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 9662 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 150 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 5209 Electrical Symbols Part 2 Page 5096 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 13013 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 10128 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 4261 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 15564 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 12821 1. Position the fascia to the vehicle, ensuring that the body side attachment tabs are fully seated. 2. Install the 4 push-pins that retain the bottom of the fascia to the headlamp panel assembly. 3. Install the push-pins (3) that retain the fascia to the fascia support rods (2). 4. Install the air defector. 5. Install the cornering lamps. 6. Install the fog lamps. 7. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the 2 bolts that retain the top of the fascia to the headlamp panel assembly. Tighten the bolts to 10 N.m (89 lb in). 9. Install the push-pin that retains the center of the top of the fascia to the headlamp panel assembly. 10. Install the grille. Page 4974 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 14229 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 7605 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 5053 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13955 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15513 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 15179 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 3604 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5701 Equivalents - Decimal And Metric Part 1 Page 1698 Electrical Symbols Part 5 Page 6977 Fluid Transfer Tube: Service and Repair Filler Tube and Seal Replacement Removal Procedure 1. Remove the filler tube indicator. 2. Remove the nut (2) securing the filler tube to the exhaust manifold stud (1). 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Position a drain pan under the vehicle. 5. Remove the filler tube (1) and seal (2) from the vehicle. Installation Procedure AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 2009 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 6967 Disclaimer Page 13493 Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts retaining the rear of the floor console bracket to the floor weld studs. Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the child restraint tether anchors. 9. Install the bussed electrical center. 10. Install the tool kit carrier. 11. Install the 3 tool carrier nuts to the floor studs. Tighten the nuts to 7 N.m (62 lb in). 12. Install the lower rear quarter trim panels. 13. Install the center pillar trim panels. 14. Install the lift gate door sill plate. 15. Install the rear door sill plates. 16. Install the front door sill plates. 17. Install the front bucket seats. 18. Instal the seat back, right and left side. 19. Install the navigation control processor bracket to the floor panel. 20. Install the rear seat cushions. 21. Install the communication interface module. 22. Install the front seats. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 14022 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Page 1447 Electrical Symbols Part 1 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 9909 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 7300 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON- III transmission fluid. Page 12769 Auxiliary Step / Running Board: By Symptom Technical Service Bulletin # 02-08-61-002 Date: 020601 Body - Assist Step Skid Pad Warping File In Section: 08 - Body and Accessories Bulletin No.: 02-08-61-002 Date: June, 2002 TECHNICAL Subject: Assist Step Skid Pad Warping (Replace Skid Pad) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Side Step Running Board (RPO BVE) Built Prior to May, 2002 Condition Some customers may comment that the assist step skid pad is warped. Cause The fasteners on the bottom side of the skid pad have interference to the attaching slots in the metal plate of the step assembly. This interference causes the pad to warp between the fasteners when exposed to sun and heat. Correction A new assist step skid pad has been released for service to correct this condition. This new pad has revised fasteners that provide more clearance to the attaching slots in the metal plate. Replace the assist step skid pads using the procedure and part numbers listed below. 1. Remove the assist step skid pad using a door trim panel tool. 2. Install the new assist step skid pad. Ensure all fasteners are fully seated. 3. Repeat the above steps for the opposite side. Parts Information Parts are currently available from GMSPO. Warranty Information Page 8439 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 6904 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 7277 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 3958 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 1588 Oxygen Sensor: Locations Locations View A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 4091 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 10373 For vehicles repaired under warranty, use the table. Disclaimer Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer A/T - Fluid Oil Cooler Flush Transmission Cooler: All Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 11475 All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Procedure Important Head the following three steps completely before attempting the procedure. Perform the following inspection procedure on the driver's and front passenger seat belts. 1. Open the driver's door and Buckle The Seat Belt. 2. Using your RIGHT hand, begin SLOWLY pulling the seat belt out of the seat back. When you have pulled out approximately 12 inches, firmly strike the inboard side of the head restraint with your LEFT hand while continuing to slowly pull out the seat belt. ^ If the seat belt locked up and stopped you from pulling the seat belt out in one continuous motion, the locking feature is working as designed and the seat belt does not need to be replaced. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. ^ If the seat belt did not lock up and you were able to pull the seat belt out in one continuous motion, the seat belt retractor requires replacement. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. Page 750 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 4095 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 14791 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Procedures Headliner: Procedures Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. NOTE: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the instrument panel (IP) trim pad. 10. Open the IP compartment door and lower the door to the full down position. 11. Disconnect the coax cable (2) and the headliner harness electrical connector (1), located near the bottom of the HVAC blower motor. 12. Remove the lower rosebud (2) that fastens the headliner harness to the cowl. 13. Remove the 3 clips (1) retaining the headliner harness to the right windshield pillar. 14. Attach a mechanic's wire to the end of the headliner harness. 15. The wire harness is routed through the cowl insulation access hole, behind the IP. In order to remove the wire harness, grasp the headliner harness near the bottom of the windshield and carefully pull upward. Page 1699 Electrical Symbols Part 6 Page 10132 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3635 6. Install the outlet radiator hose (1). 7. Reposition the outlet radiator hose clamp (1 ) using J38185. 8. Connect the transmission cooler lines to the radiator. 9. Install the lower radiator support shield, if equipped. 10. Lower the vehicle. 11. Install the coolant recovery hose to the radiator. 12. Install the radiator support diagonal brace. 13. Fill the cooling system. 14. Inspect the transmission fluid level. Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 4193 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 8022 Fluid - Transfer Case: Service and Repair Transfer Case Fluid Replacement (Trailblazer Ext, Envoy XL) Transfer Case Fluid Replacement (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the drain plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drain plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 3. Fill the transfer case with the proper fluid. Page 12555 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 15420 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 13616 5. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. IMPORTANT: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. 6. Position the wire harness retaining clip between the headliner and the roof panel. 7. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. Page 11727 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Customer Safety Information Seat Belt: Customer Safety Information CAUTION: ^ To help avoid personal injury from unrepaired crash damage to a restraint system, perform the seat belt check for each seat belt system. Replace the seat belt system If there is any doubt about the condition Of system components. ^ A child in a rear-facing child restraint can be seriously injured if the right front passengers air bag inflates. This is because the back Of a rear-facing child restraint would be very close to the inflating air bag. NEVER use a rear-facing child restraint in this vehicle. If a forward-facing child restraint is suitable for your child, ALWAYS move the front passenger seat as far back as it will go and then Install the child restraint. Be sure the child restraint position does not conflict with any additional requirements provided by the manufacture. For more information, refer to the vehicle owners manual and the instruction that came with the child restraint. ^ Perform this test in an area clear Of other vehicles or obstructions. Do not conduct this test on the open road. A large, empty parking lot is suitable. Failure to observe this precaution may result in damage to the vehicle and possible personal injury. ^ Restraint Systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: ^ Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people Of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. ^ Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. ^ Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. ^ Replace any seat belt system if you are doubtful about Its condition. This not only Includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been In a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. Seat Belt Service Precautions ^ Do not bleach or dye the seat belt webbing. Use only the following items in order to clean the seat belt webbing: ^ A mild soap and water solution ^ A soft brush or cloth ^ Keep sharp edges and damaging objects away from the seat belts. Do not bend or damage any part of the seat belt buckle or latch plate. Replace any seat belts that are cut or otherwise damaged in any manner. ^ Use only the correct seat belt anchor fasteners. Begin tightening the seat belt anchor fasteners by hand in order to ensure that the bolt is threaded straight. Tighten the correct seat belt anchor nut to the correct torque value. Refer to Fastener Tightening Specifications. ^ Some seat belts and retractors require service as a set with service replacement components only. Do not repair individual components that require service as a set. ^ Verify that the replacement part number is correct for the vehicle at that seating position. Do not substitute a seat belt from a different seating position. ^ Replace any seat belts that have a visible Caution label instructing replacement. ^ Some seat belts have an Energy Management Loop. An Energy Management Loop is an overlap of the seat belt webbing that is stitched together. If any separated stitching exists, replace the seat belt. AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 4185 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 3975 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15427 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 12343 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 5865 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or A/T - Oil Cooler Flushing Frequently Asked Questions Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Page 7054 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 4284 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 3687 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 303 Parts Information Page 3805 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 800 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11449 13. Carefully remove the seat back cover from behind the trim edge of side impact air bag module. Important When separating the seat cover hook and loop retaining strip in the next step, do not pull the adhesive-backed strip from the pad. 14. Using a side-to-side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. 15. From the bottom of the seat back, place your hand up the front side of the seat back cover and release the hook and loop fasteners that attach the seat back cover to the foam pad. 16. Starting at the bottom of the seat back, remove the seat back cover by pulling the cover upwards. The bottom of the cover should be turning inside out as the cover rolls upwards. Important Do not remove the three hog rings that attach the cover to the foam pad. 17. Continue pulling the seat back cover upwards until the top of the seat belt retractor is accessible. 18. If equipped, disconnect the seat back heating element electrical connector. 19. Remove the two head restraint retainers from the top of the seat back. 20. Reposition the cover and pad as necessary. Page 11912 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Interior - Headliner Sags at Rear of Sunroof Headliner: Customer Interest Interior - Headliner Sags at Rear of Sunroof File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-004 Date: May, 2002 TECHNICAL Subject: Headliner Sag at Rear of Sunroof Opening (Replace Velcro(R) Patches) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the headliner sags at the rear of the sunroof opening. Cause The Velcro(R) patches on the underside of the sunroof module may have been installed off location. The Velcro(R) patches on the sunroof module and the headliner may not align. Correction 1. Carefully pull down the headliner at the rear of the sunroof opening and verify the alignment between the Velcro(R) patches on the sunroof module and the headliner. 2. If the patches are misaligned, insert a small block of wood between the roof and the headliner in order to provide access to the patches. 3. Remove the patches on the sunroof module. 4. Clean the surface of the sunroof module using one the cleaners listed below. 5. Install two new Velcro(R) patches, from the service kit (P/N 88952325), on the sunroof module making sure the patches are properly aligned with the headliner patches. 6. Remove the block of wood and push the headliner back in place so that the Velcro(R) patches are fully engaged. Cleaners ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve Stock BSS ^ Kent Acrosol Parts Information Parts are currently available from GMSPO. Warranty Information Page 4327 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Propshaft Speed Sensor - Front Page 15374 Tachometer: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 15084 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Page 15044 Page 11578 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Page 284 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 288 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 14608 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 482 Endgate Module (EGM) C2 (XUV) Part 1 Page 12834 1. Position the fascia to the vehicle impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper retaining bolts to the fascia. Tighten the bolts to 2.5 N.m(22 lb in). 3. Install the screws that retain the fascia to the wheelhouse flanges. Tighten the screws to 2 N.m (18 lb in). 4. Install and fully seat the lower push-pins. 5. Install the backup lamp socket assemblies. Diagram Information and Instructions Speedometer Head: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Fuse Block - Rear Fuse Block: Diagrams Fuse Block - Rear Fuse Block - Rear C1 Part 1 Page 9955 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 14217 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 11267 Side Air Bag: Service and Repair Deployment Procedures Deployment Outside Vehicle TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ J 39401-B SIR Deployment Fixture ^ An appropriate pigtail adaptor CAUTION: Refer to SIR Inflator Module Disposal Caution in Service Precautions. 1. Deployment and disposal of a malfunctioning inflator module is not subject to any required retention period. Deploy the inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following situations: ^ Using the SIR diagnostics, you determine that the inflator module is malfunctioning. ^ The inflator module is cosmetically damaged, i.e., scratched or ripped. ^ The inflator module pigtail, if equipped, is damaged. ^ The inflator module connector is damaged. ^ The inflator module connector terminals are damaged. CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. 2. Before you begin to remove the inflator module, turn OFF the ignition. 3. Remove the ignition key. 4. Put on safety glasses. 5. Remove the inflator module. ^ If you are removing the steering wheel module, refer to Inflatable Restraint Steering Wheel Module Replacement. ^ If you are removing the IP module, refer to Inflatable Restraint Instrument Panel Module Replacement. ^ If you are removing the side impact module- left, refer to Inflatable Restraint Side Impact Module Replacement - Front. 6. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor or deployment fixture. Page 13218 Do not use oxyacetylene welding equipment. MIG WELD ONLY. Weld the crack/four holes that were drilled through the inner panel using the appropriate welding technique. Prior to refinishing, refer to the GM4901M-D-2006 (English) or GM4901M-D-F2006 (French) GM Approved Refinish Materials booklet for recommended products. The GM Refinish Materials information is now on the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: Go to www.gmgoodwrench.com. Click on GM Parts and Accessories link. Click on GM Technical Repair Information. Click on Paint Shop. Clean and prepare all of the welding surfaces. Return the surface to its original contour. Spot paint and clear the area around the hinges. Reinstall the liftgate. Replace the upper two bumpers and inspect the lower two bumpers. Replace as necessary. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12300 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 12899 16. Refinish as necessary. 17. Install and align all of the related panels and components. Page 12253 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 15409 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12356 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 4695 Electrical Symbols Part 7 Page 8669 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Page 15303 Electrical Symbols Part 5 Page 14751 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 3719 1. Install a new water pump gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump and secure the water pump with the bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 3. Install the water pump pulley. 4. Install the water pump pulley bolts. 5. Using the J 41240, secure the water pump pulley while tightening the water pump pulley bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J41240. 7. Install the drive belt. 8. Install the fan and the shroud. 9. Fill the cooling system with the specified coolant and concentration. 10. Inspect for leaks. Page 1738 Electrical Symbols Part 4 Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal and Housing Replacement ^ Tools Required J 36660-A Torque Angle Meter - J 44219 Cover Alignment Pins - J 44227 Rear Seal Installer Removal Procedure 1. Remove the transmission. 2. Remove the fly wheel bolts and remove the fly wheel. 3. Remove the crankshaft rear oil seal housing bolts. 4. Install two bolts into the jackscrew holes (1) to release the cover from the block. 5. Remove the crankshaft and rear oil seal housing. 6. Remove the oil seal from the crankshaft snout. Installation Procedure Page 3262 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 10054 3. Lubricate the O-ring seal (3) with power steering fluid. 4. Install the O-ring seal (3). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the connector and fitting assembly (3) to the pump housing (1). Tighten the connector and fitting assembly (3) to 75 Nm (55 ft. lbs.). Page 4710 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9056 Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement (Rear Disc Brakes) Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Release the park brake, if applied. 2. Raise and the vehicle. Refer to Vehicle Lifting. 3. Remove the wheel and the tire. Important: In the following service procedure, the brake caliper and mounting bracket does not have to be separated. Relocated the brake caliper and bracket to the side and secure. 4. Remove the brake caliper and bracket. 5. Remove the brake rotor. Page 687 For vehicles repaired under warranty, use the table. Disclaimer Page 14341 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 14991 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 7909 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 10088 6. Remove the support from the power steering gear. 7. Install the power steering hose assembly to the power steering gear. 8. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (9 ft. lbs.). 9. Install the steering gear crossmember. 10. Connect the lower intermediate shaft to the power steering gear. 11. Install the lower intermediate shaft retaining bolt to the power steering gear. Tighten the lower intermediate shaft retaining bolt to the power steering gear to 40 Nm (30 ft. lbs.). 12. Connect the outer tie rods to the steering knuckles. 13. Install the outer tie rods to steering knuckles retaining nuts. Tighten the outer tie rods to steering knuckles retaining nuts to 45 Nm (33 ft. lbs.). 14. Install the tires and wheels. 15. Remove the drain pan from under the vehicle. 16. Lower the vehicle. Page 14920 Electrical Symbols Part 2 Page 8748 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Testing and Inspection Mirror Memory Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Doors; Testing and Inspection. Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 1867 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 11608 Alarm Module: Service and Repair Theft Deterrent Module Replacement THEFT DETERRENT - IMMOBILIZER THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the upper and lower trim covers. 3. Remove the lock cylinder. 4. Disconnect the connector from the theft deterrent control module. 5. If necessary, disconnect the connector from the ignition lock cylinder case (1). 6. Remove the theft deterrent control module (2) from ignition lock cylinder case assembly (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2) onto the ignition lock cylinder case assembly (1). CAUTION: Refer to SIR Inflator Module Coil Caution in Service Precautions. 2. Connect the connector to the theft deterrent control module. 3. If necessary, connect the connector to the ignition lock cylinder case. 4. Install the lock cylinder. Page 3909 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11745 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 15346 Electrical Symbols Part 7 Page 1356 Turn Signal/Multifunction Switch C4 Windshield Wiper Washer Switch (Multifunction Switch C3) Page 15695 Various symbols are used in order to describe different service operations. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 12450 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Transfer Case Shift Control Module C1 Page 7653 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 2788 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 11234 3. If installing the existing inflatable restraint steering wheel module coil, it must be centered first. Refer to Inflatable Restraint Coil Centering - Off Vehicle (Column Shift And Floor Shift). 4. Align the inflatable restraint steering wheel module coil (2) with the horn tower sticking through the shaft lock or cam orientation plate (1). 5. Slide the inflatable restraint steering wheel module coil (2) onto the steering shaft assembly. 6. Remove and discard the centering tab from the new inflatable restraint steering wheel module coil. IMPORTANT: The retaining ring (1) must seat securely on the groove of the race and upper shaft assembly (2). 7. Install the retaining ring (1) using snap ring pliers. CAUTION: Refer to SIR Inflator Module Coil Caution in Service Precautions Page 2481 Disclaimer Page 4417 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 4969 Electrical Symbols Part 8 Page 8176 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test ^ Tools Required J 35667-A Cylinder Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the diagnosis. The cylinder leakage test may be used in conjunction with the engine compression test, to isolate the cause of leaking cylinders. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the battery ground (negative) cable. 2. Remove the spark plugs. 3. Install J 35667-A. 4. Measure each cylinder on the compression stroke, with the valves closed. Important: It may be necessary to hold the crankshaft balancer bolt, to prevent piston movement. 5. Apply air pressure, using J 35667-A. Refer to the manufacturer's instructions. 6. Record the cylinder leakage readings for each cylinder. Important: ^ Normal cylinder leakage is from 12 to 18 percent. ^ Make a note of any cylinder with more leakage than the other cylinders. ^ Any cylinder with 30 percent leakage or more requires service. 7. Inspect the four primary areas, to properly diagnose a leaking cylinder. 8. If air is heard from the intake or exhaust system, perform the following procedure: ^ Remove the camshaft cover. Ensure the valves are closed. - Inspect the cylinder head for a broken valve spring. ^ Remove the cylinder head and inspect. 9. If air is heard from the crankcase system at the crankcase (oil filler tube), perform the following procedure: ^ Remove the piston from the suspect cylinder. ^ Inspect the piston and connecting rod assembly. ^ Inspect the engine block. 10. If bubbles are found in the radiator, perform the following procedure: ^ Remove the cylinder head and inspect. ^ Inspect the engine block. 11. Remove the J 35667-A. 12. Install the spark plugs. 13. Install the battery ground (negative) cable. Page 10403 1. Install the shock module yoke to the lower control arm stud and shock absorber. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten the shock module yoke to shock absorber pinch bolt to 70 Nm (52 ft. lbs.). 3. Install the shock module yoke to lower control arm mounting nut. Tighten the shock module yoke to lower control arm mounting nut to 110 Nm (81 ft. lbs.). 4. Install the tire and wheel. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Page 11081 Low Pressure Sensor / Switch: Locations Locations View - HVAC Systems - Manual Page 7075 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 3288 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. Page 4021 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 402 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 13692 Electrical Symbols Part 6 Page 15129 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15483 Volt Meter Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 15497 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 4863 Electrical Symbols Part 7 Page 13575 20.2. Remove the navigation antenna cable from the right side door rocker panel attachments. 20.3. Remove the navigation antenna cable from the right center pillar. 21. Remove the following headliner harness clips from the left center pillar: ^ The center pillar harness clips (4) ^ The center pillar harness clips (3) ^ The center pillar harness clips (1) 22. Remove the center pillar harness ground bolt (2). 23. Remove the harness from the left center pillar. 24. Remove the rear seats. 25. Remove the headliner harness retaining clips (2) from the rocker panel and floor panel. 26. Remove the center pillar headliner harness electrical connector from the bussed electrical center, and the block base from the floor panel. 27. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. Page 3925 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4619 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 14186 3. Install the 3 bolts that retain the head restraint retractor assembly to the seat back frame. Tighten the head restraint retractor bolts to 10 N.m (88 lb in). 4. Install the seat back cover and pad. Head Restraint Guide Assembly Replacement - Rear No. 2 Head Restraint Guide Assembly Replacement - Rear No. 2 Removal Procedure 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad to expose the seat back frame. 3. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 4. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. Installation Procedure 1. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 2. Install the seat back cover and pad on the seat back frame. 3. Install the head restraint assembly. Page 3538 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Page 6048 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Radiator Support Shield Replacement Skid Plate: Service and Repair Radiator Support Shield Replacement Radiator Support Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the radiator support shield mounting nuts and bolts. 3. Remove the radiator support shield. Installation Procedure 1. Remove the radiator support shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Remove the radiator support shield mounting nuts and bolts. Tighten the radiator support shield mounting nuts to 16.5 N.m (12 lb ft). 3. Lower the vehicle. Page 138 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 8815 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. Page 13461 Remove the auxiliary seal and the auxiliary seal retainer. Clean the surface and fill the void with Medium Body Seam Sealer, P/N 12378500 (in Canada, P/N 10952233). Let stand for 60 minutes and touch up. Correction 2 Remove the auxiliary seal and the auxiliary seal retainer. Clean the area with a non oil base cleaner and fill the void with urethane sealer. Correction 3 Install four new plastic nuts in the "A" Pillar. The new nuts have a foam gasket that seals the perimeter when seated. Correction 4 Seat the push-in retainers fully at the bottom of the "A" pillar. Correction 5 Apply weatherstrip adhesive inside the primary seal retainer. Seal the retainer from the top of the dash to the bottom of the "A" pillar. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13345 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Page 9242 Alternator: Service and Repair GENERATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the drive belt. 3. Disconnect the battery positive cable nut (1) on the generator. 4. Remove the A/C line mounting bracket bolt at the engine life hook. Page 10179 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling-Colder plug ^ Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 3151 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 11982 Parts Information Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Front Outside Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the rear half of the water deflector from the door. 4. Release the upper lock rod retainer (1) from the rod. 5. Remove the lock rod from the handle assembly. 6. Release the lock cylinder rod retainer (2) from the lock rod, if equipped. 7. Remove the lock cylinder rod from the handle assembly. 8. Remove the 2 door handle retaining nuts. 9. Remove the handle assembly from the door. 10. Remove the lock cylinder from the handle. Installation Procedure 1. Install the lock cylinder to the handle. 2. Install the handle assembly to the door. 3. Install the upper lock rod to the handle assembly. 4. Install the lock rod retainer (1). 5. Install the lock cylinder rod to the handle assembly. 6. Install the cylinder lock rod retainer (2). Notice: Refer to Fastener Notice in Service Precautions. 7. Install the 2 door handle retaining nuts. Tighten the nuts to 10 N.m (88 lb in). 8. Attach the rear half of the water deflector to the door. 9. Install the door trim panel. Page 11766 For vehicles repaired under warranty, use the table. Disclaimer Page 6057 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 564 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 1611 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Recall 04V201000: Possible Seat Belt Sensor Malfunction Seat Belt: All Technical Service Bulletins Recall 04V201000: Possible Seat Belt Sensor Malfunction DEFECT: Certain sport utility vehicles do not conform to Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." One of the two sensors in the driver's and front passenger's seat belt retractor could be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as heavy braking, may not operate as intended. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of an injury. Remedy: Dealers will inspect the seat belt assemblies to determine proper vehicle sensor function. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Oldsmobile at 1-800-630-6537.. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Clutch: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 5940 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 12947 Front Door Striker: By Symptom Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Oil Pressure Diagnosis Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following can cause low or no oil pressure: Low oil level-fill to the full mark on the oil level indicator. - Slow idle speed - Incorrect or malfunctioning oil pressure switch- replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gage- replace the oil pressure gage. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if it is diluted. - The oil pump is worn or dirty-clean or replace the oil pump. - The oil filter is plugged-replace the oil filter. - The oil pickup screen is loose or plugged- replace the oil pickup screen. - A hole in the oil pickup tube-replace the oil pickup tube. - Excessive bearing clearance-replace the bearings. - Cracked, porous, or plugged oil galleries-repair or replace the engine block. - The gallery plugs are missing or improperly installed-install or repair as necessary. - The pressure regulator valve is stuck. Check the pressure regulator valve for sticking in the bore. - Check the bore for scoring and burrs. - The camshaft is worn or poorly machined- replace the camshaft. - Worn valve guides-repair as needed. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Locations Locations View Page 10094 Steering Gear: Service and Repair Tie Rod Replacement - Inner Tie Rod Replacement - Inner Tools Required ^ J34028 Inner Tie Rod Wrench Removal Procedure Important: The boot and retaining clamps must be replaced when replacing the inner tie rod. 1. Remove the rack and pinion boot. 2. Place the gear in a vise. Important: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. This could result in damage to both the pinion and the steering gear. 3. Separate the shock dampener (4) from inner tie rod assembly (2). 4. Slide the shock dampener back on the rack (3). Important: The pipe wrench must be placed at the valve end of the steering gear (1) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (1). 5. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). 6. Place a wrench on the flats of the inner tie rod housing (2). 7. Rotate the inner tie rod housing (2) counterclockwise until the inner tie rod separates from the rack (3). 8. At the other gear end, separate the shock dampener (3) from inner tie rod assembly (2). 9. Slide the shock dampener (3) back on the rack (4). Important: The pipe wrench must be placed at the valve end of the steering gear (5). Placing the pipe wrench in any other location will cause damage to the steering gear (5). Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 4224 Accelerator Pedal Position (APP) Sensor Page 1169 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Page 9701 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 157 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 8938 5. Install the rear brake rotor. 6. Install the brake caliper and bracket assembly. 7. Install the park brake cable to the rear brake caliper. 8. Adjust the park brake shoe. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Page 14384 15. Spread the pad apart and push the cover and pad up over the seat back in order to expose the head restraint guides. 16. Remove the head restraint guides by squeezing the locking tabs together and pulling the restraint guides upward and out of the seat frame. 17. Remove the seat back cover the remainder of the way from the seat back. 18. Disconnect the electrical connector for the seat back heating element, located near the seat belt retractor, if equipped. 19. Carefully remove the seat back pad from the seat back frame. INSTALLATION PROCEDURE 1. Position the seat back pad to the seat back frame. 2. Connect the electrical connector to the seat back heating element, if equipped. 3. Partially install the seat back cover over the top of the seat. 4. Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The guide with the release tab goes on the right-hand side. Page 12371 Parts Information Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 8052 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12518 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 3014 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 5231 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Recall 04V527000: Stop/Tail Lamp Inspect/Replace Brake Lamp: All Technical Service Bulletins Recall 04V527000: Stop/Tail Lamp Inspect/Replace Make / Models : Model/Build Years: Buick / Rainier 2004 Chevrolet / TrailBlazer 2002-2004 Chevrolet / TrailBlazer ext 2002-2004 GMC / Envoy XL 2002-2004 Oldsmobile / Bravada 2002-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V527000 Recall Date : OCT 27, 2004 COMPONENT: EXTERIOR Lighting: Brake Lights Potential Number Of Units Affected : 871473 SUMMARY: On certain sport utility vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. CONSEQUENCE: An inoperative brake lamp will not convey the driver's intention of stopping to drivers in following vehicles, and an inoperative rear turn signal lamp will not convey the driver's intention to turn to drivers in following vehicles. Both of these failures can increase the risk of a crash. REMEDY: Dealers will inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. the recall began on November 22, 2004. Owners should contact Chevrolet at 1-800-630-2438, Oldsmobile at 1-800-630-6537, Buick at 1-866-608-8080, or GMC at 1-866-996-9463. NOTES: GM Recall NO. 04087. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 9780 C312 Part 2 C313 Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 8904 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 14998 Fuel Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 5981 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 3914 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13812 Disclaimer Page 10258 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 6362 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13771 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Refer to Wiper Motor Replacement - Rear. Page 6753 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Transfer Case Shift Control Module C1 Page 9940 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by loosening the lower control arm adjustment bolts and repositioning the lower control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are given under Ride/Trim Height Specifications. 1. For an accurate reading, do not push or pull on the tires during the alignment process. View Of Left Front Wheel From Left Side Of Vehicle 2. Determine the caster angle. View Of Front Wheel From Front Of Vehicle 3. Determine the camber angle. Page 11421 All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Procedure Important Head the following three steps completely before attempting the procedure. Perform the following inspection procedure on the driver's and front passenger seat belts. 1. Open the driver's door and Buckle The Seat Belt. 2. Using your RIGHT hand, begin SLOWLY pulling the seat belt out of the seat back. When you have pulled out approximately 12 inches, firmly strike the inboard side of the head restraint with your LEFT hand while continuing to slowly pull out the seat belt. ^ If the seat belt locked up and stopped you from pulling the seat belt out in one continuous motion, the locking feature is working as designed and the seat belt does not need to be replaced. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. ^ If the seat belt did not lock up and you were able to pull the seat belt out in one continuous motion, the seat belt retractor requires replacement. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. Page 13565 34. Remove the headliner harness from the left-hand third pillar. 35. Remove the headliner harness from the floor studs. 36. Remove the third pillar headliner harness electrical connector from the body electrical block, and the block base from the floor panel. 37. Reach underneath the carpet and disconnect the 6 way headliner harness electrical connector (1) from the cross-body wire harness. 38. Remove the navigational antenna cable from the right-hand third pillar. 39. Remove the navigational antenna cable from the floor studs. Page 9296 Electrical Symbols Part 6 Page 1599 Electrical Symbols Part 8 Page 2838 Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Service and Repair Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 15570 Page 13197 Endgate Module (EGM) C2 (XUV) Part 1 Page 10055 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement Power Steering Pulley Replacement Tools Required ^ J25033-C Power Steering Pump Pulley Installer ^ J25034-C Power Steering Pump Pulley Remover Removal Procedure 1. Remove the upper radiator air intake baffle. 2. Remove the drive belt. 3. Remove the power steering pump pulley using J25034-C. Installation Procedure 1. Install the power steering pump pulley to the end of the power steering pump shaft. 2. Install the power steering pump pulley to the power steering pump using J25033-C. A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Hood Hinge Bracket Hood Hinge: Service and Repair Hood Hinge Bracket Hood Hinge Bracket REMOVAL PROCEDURE 1. Remove all of the related panels and components. 2. Restore as much of the damage as possible to the factory specifications. 3. Note the location and remove the following as necessary: - Sealers - Sound deadeners - Anti-corrosion materials IMPORTANT: Do not damage any of the inner panels or reinforcements. Drill through the hinge bracket only. 4. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part. 5. Remove the Hood Hinge Bracket. INSTALLATION PROCEDURE Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the 2HI position. 1. Raise the vehicle. 2. Remove the fuel tank shield, if equipped. 3. Disconnect the motor/encoder electrical connector (1). 4. Remove the motor/encoder mounting bolts. Page 6998 Disclaimer Page 1810 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14641 Front Door Weatherstrip: Service and Repair Weatherstrip Side Retainer Replacement Weatherstrip Side Retainer Replacement Removal Procedure 1. Open the front door. Remove the push pin retainers (2) from the front door sealing weatherstrip located at the base of the pillar. 2. Pull back the front door sealing weatherstrip (1) in order to expose the weatherstrip side retainer screws (2). 3. Remove the screws from the weatherstrip side retainer. 4. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer (2) to the windshield pillar. Page 12525 Page 5321 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4613 Electrical Symbols Part 7 Page 4629 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5863 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9706 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 14497 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Procedures Luggage Rack: Procedures Luggage Carrier Replacement REMOVAL PROCEDURE 1. Using a flat bladed tool, carefully remove the finish covers (3) from the luggage carrier side rails (2). 2. Unlock the cross rails (4) by releasing the locking tab (1) on the end of each cross rail. 3. Slide the cross rails forward and remove from the side rails. 4. Remove the bolts that retain the side rails to the roof panel. 5. Remove the side rails from the roof panel. INSTALLATION PROCEDURE 1. Position the side rails (2) to the roof panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the side rails to the roof panel, starting with the rearmost bolt first on each side. Tighten Tighten the luggage carrier side rail bolts to 5 N.m (44 lb in). IMPORTANT: Ensure that the loops on the cross rails are indexed toward the front of the vehicle. 3. Install the cross rails (4) to the side rails. 4. Lock the cross rails to the slide rails. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 11512 Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the grille. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) or Grille Replacement (Oldsmobile) in Exterior Trim. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end discriminating sensor. Engine Controls - Underhood Ticking Noise Fan Clutch: Customer Interest Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 397 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 139 Page 3921 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 132 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 4406 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 8389 5. Remove the motor/encoder assembly. Important: When replacing the encoder rotary position sensor follow these additional steps. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder gasket. 6. Position the motor on a work bench. 7. Release the 4 tabs that retain the motor/encoder gasket and remove the gasket (1). 8. Remove the snap ring and washer retaining the motor/encoder rotary position sensor. Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed. 9. Lift the motor/encoder rotary position sensor (2) from the motor shaft. 10. Disconnect the rotary position sensor (2) from the wiring harness. Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed. Installation Procedure Important: Provided the rotary position sensor was removed, follow steps to install the sensor, otherwise proceed to installing the motor/encoder to the transfer case. 1. Connect the wiring harness to the rotary position sensor. 2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 10644 Air Door Actuator / Motor: Description and Operation HVAC System - Automatic Air Temperature Actuator Description and Operation AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The doer position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AUXILIARY AIR TEMPERATURE ACTUATOR-VIN 6 The auxiliary air temperature actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to coordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 court range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. HVAC Control Components DEFROST ACTUATOR The defrost actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the coor position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. MODE ACTUATOR The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AUXILIARY MODE ACTUATOR-VIN 6 The auxiliary mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to coordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. Page 12546 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 3334 Page 247 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 1400 Electrical Symbols Part 7 Page 4336 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components ^ For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). ^ For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Exhaust - Exhaust Noise/Leak Exhaust Manifold Gasket: All Technical Service Bulletins Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 283 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 13253 Tighten the pullstrap screw to 4 N.m (35 lb in). 5. Close the liftgate. 6. Open the liftgate window. 7. Install the push-pin retainer. 8. Close the liftgate window. Page 6727 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1031 16. Inspect the inside of the electrical connector on the wiper motor for moisture or water. If no moisture or water is found, continue inspecting for evidence or signs that moisture or water was present at some earlier time. Indicators include water stains, dried dirt, etc. (1). ^ If moisture or water is found in the electrical connector, or if there is evidence that there was moisture or water present at an earlier time, the complete wiper motor module (including the motor) MUST be replaced. Obtain a new wiper module and proceed to Step 20. The new wiper modules already have a different style of breathable seal on the wiper cover. DO NOT install the breathable seal described later in this recall on new wiper modules. ^ If there is no moisture or water found in electrical connector, or if there is NO evidence that moisture or water was present at an earlier time, a breathable seal must be installed over the vent in the wiper motor cover. Proceed to the next step. 17. Clean the exterior surface of the wiper motor cover thoroughly (1). It must be free of dirt, grease, oil, and other contamination. Important To ensure good adhesion of the seal being installed in the next steps, make sure that your hands are clean and free of oil and grease before proceeding. 18. Using the alcohol wipe included in the kit, wipe the complete exterior surface of the wiper cover thoroughly. Allow the surface to dry approximately 30-45 seconds before proceeding. Important When using the adhesion promoter in the next step: ^ DO NOT open the adhesion promoter until you are ready to apply it. ^ Use the complete contents of the packet as soon as it is opened. ^ If the packet is dried-out when opened, obtain another sealer kit or use P/N 12378462 (4 oz. can of adhesion promoter). ^ Do not allow the liquid to "spill" inside of the vent opening on the wiper motor cover when applying. ^ Allow to dry 30-90 seconds before applying the seal. 19. Carefully apply the adhesion promoter that is included in the kit. Important The seal must be inspected before installing. If there are any creases in the seal or backing material, the seal must NOT be used. Obtain another sealer kit. ^ If you are unable to remove the backing material from the seal in the next step, the seal is beyond its shelf life of one year. Obtain another sealer kit. Do NOT touch the adhesive surface on the seal when removing the backing material. Page 7440 For vehicles repaired under warranty, use the table. Disclaimer Page 7844 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Radio Speakers - Intermittent, Random Noises Speaker: Customer Interest Radio Speakers - Intermittent, Random Noises File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-013 Date: October, 2001 TECHNICAL Subject: Noise Heard in Radio Speakers (Replace Amplifier or Repair Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Premium Sound (RPO UQA) This bulletin provides information on two different conditions. Condition 1 Some customers may comment about intermittent static, popping, thumping or booming noises randomly heard in any or all speakers. This condition generally occurs in warmer climate areas. Cause Overheating of the radio amplifier due to ambient and operational temperatures may cause this condition. Correction An improved radio amplifier is now available from GMSPO. Replace the radio amplifier. Refer to the Entertainment sub-section of the Service Manual for the Amplifier Replacement procedure (SI2000 Document ID # 717628). Condition 2 Some customers may comment about consistent static, popping, thumping or booming noises heard in the same speaker repeatedly. Cause This condition may be caused by the radio amplifier wiring harness being pinched by the passenger side rear seat attachments, resulting in damage to the wires. Correction Repair any damaged wires using the procedure listed below. 1. Remove the right rear seat back. Refer to the Seats sub-section of the Service Manual for the Seat Back Replacement procedure (SI2000 Document ID # 741140). 2. Remove the right rear door sill plate. 3. Pull back the carpet in order to access radio amplifier harness. Page 15807 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Locations Locations View - HVAC Systems - Manual Page 1339 Conversion - English/Metric Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 12827 4. Position the fascia support rods (2) to the impact bar (5). 5. Install the bolts (2) which retain the fascia support rods to the impact bar. Tighten the bolts to 10 N.m (89 lb in). 6. Install the front fascia. Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Assembly to Case Bolt ......................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Page 13132 9. Apply sealers and refinish as necessary. 10. Install all of the related panels and components. Page 3688 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15270 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 7228 6. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount. 2. Install the bolts (1,2) securing the transmission mount to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.) 3. Install the transmission support to the vehicle. Page 2776 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 5402 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 14609 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 463 Locations View Page 4233 Electrical Symbols Part 2 Page 2621 Fuse Block - Rear C2 Part 1 Page 12232 Page 10754 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3252 1. Use the J 44227 to install the crankshaft rear oil seal. 2. Remove the J 44227. 3. Apply a 3 mm (0.12 inch) bead of GM P/N 12378521 to the rear oil seal housing (1). 4. Install the J 44219 guide pins into the block. Important: ^ When installing a new seal, use the plastic installation sleeve supplied with the new seal. ^ The seal installation sleeve should come off after the seal is installed. Disregard the sleeve. 5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft. 6. Install the crankshaft rear oil seal housing bolts, except the two in place of the guide pins. 7. Remove the J 44219 guide pins. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the remaining two crankshaft rear oil seal housing bolts. ^ Tighten all the oil seal housing bolts to 10 Nm (89 inch lbs.). Page 8857 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3854 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 8779 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 1653 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 460 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 11297 Knee Diverter: Service and Repair Knee Bolster Replacement REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the knee bolster trim panel. 3. Remove the 4 knee bolster retaining nuts. 4. Remove the knee bolster from the steering column support bracket. INSTALLATION PROCEDURE 1. Install the knee bolster to the steering column support bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 knee bolster retaining nuts. Tighten Tighten the nuts to 10 N.m (88 lb in). 3. Install the knee bolster trim panel. 4. Install the left closeout/insulator panel. Testing and Inspection Mirror Memory Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Doors; Testing and Inspection. Page 8159 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 13354 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 4890 Conversion - English/Metric Page 14464 1. Position the latch bracket to the seat hinge. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the latch bracket bolts (2) that retain the latch bracket to the seat hinge. Tighten Tighten the latch bracket bolts to 35 N.m (26 lb ft). 3. Install the seat back to the vehicle. Mid-Position Floor Latch Assembly Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the rear center seat belt buckle assembly from the floor latch assembly. 4. Remove the cable (3) from the mid-position floor latch assembly (2). 5. Remove the bolts (1) securing the mid-position floor latch assembly to the seat cushion frame. 6. Remove the mid-position floor latch assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 3322 13. Install the exhaust camshaft actuator into the timing chain. 14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1). Important: It may be necessary to remove the J44221 to rotate and hold the camshaft hex to align the pin to the camshaft sprocket. 15. Install the exhaust camshaft actuator onto the exhaust camshaft. Important: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt. 16. Rotate the camshaft actuator clockwise until it stops (as seen from the front of the vehicle). Notice: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. 17. Install the exhaust camshaft actuator bolt. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135°. 18. Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). ^ Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100°. 19. Remove the tee in the timing chain tensioner to regain tension on the timing chain. Page 4067 Electrical Symbols Part 8 Page 3092 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: Check the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. ^ Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 4854 Locations View AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 3681 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 14919 Electrical Symbols Part 1 Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 7074 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 13543 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 10930 Refrigerant System Capacities Page 12416 Page 4633 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10898 IMPORTANT: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. ^ For compression style fittings use a back up wrench on the fitting (2) and tighter the fitting nut (1) to specification. ^ For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 15963 Horn Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the horn relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the horn relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 5728 Electrical Symbols Part 6 Page 1477 Equivalents - Decimal And Metric Part 1 Body - Door(s) Are Difficult To Close Front Door Striker: Customer Interest Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 6890 Disclaimer Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 2195 Electrical Symbols Part 4 Page 4708 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10354 3. Connect the air spring compressor electrical connection (2). 4. Connect the air inflator switch electrical connection, air supply line, and air spring compressor vent hose to the air spring compressor. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the air spring compressor to the frame mounting bolts. Tighten the air spring compressor to the frame mounting bolts to 25 Nm (18 lb ft). 6. Lower the vehicle. 7. Install the air suspension system fuse. 8. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 9. Check D height. 10. Check for leaks. If a leak is found at the air supply lines connections at the air spring compressor, replace the air supply lines. AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 2457 Radiator Hose: Service and Repair Radiator Hose Replacement- Outlet Radiator Hose Replacement- Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. 2. Reposition the outlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the outlet radiator hose. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the lower radiator support shield, if equipped. 6. Reposition the outlet radiator hose clamp at the radiator using J 38185. 7. Remove the outlet radiator hose (1) from the radiator. Installation Procedure Page 12564 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 5141 Electrical Symbols Part 4 Page 1812 Equivalents - Decimal And Metric Part 2 Arrows and Symbols A/T - Water Or Coolant Contamination Information Transmission Cooler: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 8128 For vehicles repaired under warranty, use the table. Disclaimer CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 14767 Audible Warning Device: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 5079 Electrical Symbols Part 5 Page 11179 Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Automatic A/C LOW PRESSURE SWITCH A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 11760 For vehicles repaired under warranty use, the table. Disclaimer Page 13015 Page 1223 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement REMOVAL PROCEDURE 1. Remove the grille. 2. Remove the ambient air temperature sensor (1) to the headlamp assembly. 3. Remove the ambient temperature sensor from the panel assembly. 4. Disconnect the electrical connector from the ambient air temperature sensor. INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (1) to the headlamp assembly. 2. Connect the electrical connector to the ambient temperature sensor. 3. Install the ambient temperature sensor retaining clip to the headlamp panel assembly. 4. Install the grille. Page 10663 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator-auxiliary (1). 3. Remove the mode actuator-auxiliary (1) from the HVAC module-auxiliary. 4. Remove the retaining screws from the mode actuator-auxiliary. INSTALLATION PROCEDURE 1. Install the mode actuator (1) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator-auxiliary. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the mode actuator-auxiliary (1). 4. Install the right rear quarter trim panel. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC) in HVAC Systems - Automatic. Mode Actuator - Console REMOVAL PROCEDURE Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOL REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward in order to release Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the 5 bolts securing the heat shield to the floor panel studs. 3. Remove the heat shield from the vehicle. Installation Procedure 1. Place the catalytic converter heat shield onto the floor panel studs. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure the heat shield with the 5 bolts. ^ Tighten the catalytic converter heat shield bolts to 7 Nm (62 inch lbs.). 3. Lower the vehicle. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 15737 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Locations Locations View Page 12062 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5993 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Seat Belt Retractor Replacement - No. 2 Left Rear Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - No. 2 Left Rear REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the left rear quarter trim panel. 3. Remove the rear seat belt lower anchor nut. 4. Remove the bolt that retains the seat belt retractor assembly to the body. 5. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt retractor assembly to the vehicle. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the left rear quarter trim panel. 4. Install the rear seat belt lower anchor nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat mounting nut to 45 N.m (33 lb ft). Driver Information Center - Setting Language Options Driver/Vehicle Information Display: All Technical Service Bulletins Driver Information Center Setting Language Options File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-015 Date: October, 2001 INFORMATION Subject: Understanding Driver Information Center Personalization/Language Options Models: 2002 Chevrolet and GMC SIT Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Driver Information Center Display (RPO U68) The Driver Information Center (DIC) display on the instrument cluster has a multi-lingual capability. A vehicle owner may accidentally put the DIC into a language he or she does not understand. This may make it difficult or impossible for the owner to figure out how to get the display back to the preferred language. This difficulty is resulting in clusters being replaced at the dealer as a warranty return. Dealers should reset the DIC back to the language that the owner understands by following these steps: 1. Press and hold the personalization button (2) and the trip information button (1) at the same time. The DIC will begin scrolling through the languages. Each language will be shown in that particular language (English will be in English, French will be in French, etc.). 2. When the preferred language appears, release both buttons. The DIC will then display the information in the language that was selected. Page 7026 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Service and Repair Positive: Service and Repair REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Disconnect the battery positive cable from the battery. 3. Disconnect the harness from the engine harness bracket. 4. Disconnect the positive cable lead from the starter (1). Page 8491 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 758 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 4390 Electrical Symbols Part 1 Page 14431 4. Install the rear seat bracket with the four mounting nuts (2). Tighten the rear seat bracket mounting nuts to 25 N.m (18 lb ft). 5. Install the rear seat bracket trim covers (1). 6. Install the seat in the vehicle. Seat Cushion Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat bracket trim cover. 2. Remove the hydraulic jack from the jack stowage area, on the left side only. 3. Position the seat cushion assembly in order to gain access to the 2 rear seat mounting nuts. 4. Remove the 2 mounting nuts. 5. Remove the seat cushion assembly from the vehicle. Installation Procedure 1. Position the seat cushion assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 nuts that retain the seat cushion assembly to the floor panel. Tighten the rear seat mounting nuts to 45 N.m (33 lb ft). 3. Install the hydraulic jack into the jack stowage area, on the left side only. 4. Adjust the seat cushion assembly to the latched position. 5. Install the rear mount trim cover. Seat Cushion Bracket Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Bracket Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle.. Page 14941 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5278 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12820 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper (Chevrolet, GMC) Removal Procedure 1. Remove the grille. 2. Remove the 2 bolts that retains the top of the fascia to the headlamp panel assembly. 3. Remove the push-pin that retains the top of the fascia to the headlamp panel assembly. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the push-pins (3) that retain the fascia to the fascia support rods (2). 6. Remove the fog lamps from the fascia. 7. Remove the cornering lamps from the fascia. 8. Remove the air deflector. 9. Remove the 4 push-pins that retain the bottom of the fascia to the headlamp panel assembly. 10. Release the body side attachment tabs and pull the fascia straight forward from the wheelhouse opening in order to remove the fascia from the vehicle. Installation Procedure Page 1487 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ..................................................................... 48-54 psi KOEO Key On Engine Off Page 1906 8. Install and secure the headlamp wire harness in the retaining clip (1). 9. Install the grille. 10. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 13046 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 10633 Mode Actuator Air Temperature Actuator - Left Page 1657 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 13592 1. Disconnect the navigation antenna cable from the communication interface module. 2. Remove the navigation antenna cable from the right side door rocker panel attachments. 3. Remove the navigation antenna cable from the right center pillar. 21. Remove the following headliner harness clips from the left center pillar: * The center pillar harness clips (4) * The center pillar harness clips (3) * The center pillar harness clips (1) 22. Remove the center pillar harness ground bolt (2). 23. Remove the harness from the left center pillar. 24. Remove the rear seats. 25. Remove the headliner harness retaining clips (2) from the rocker panel and floor panel. 26. Remove the center pillar headliner harness electrical connector from the bussed electrical center, and the block base from the floor panel. 27. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 28. Disconnect the inside rear view mirror electrical connector (6). 29. Disconnect the rain sensor electrical connector, if equipped. 30. Disconnect the navigation antenna electrical connector, if equipped. 31. Remove the upper rear quarter trim panels. 32. Remove the coat hooks from the roof panel. 33. Disconnect the radio control module electrical connector from the right body side window. 34. Disconnect the radio antenna module electrical connector from the left body side window. 35. Disconnect the electrical connector from the cellular phone antenna. Page 15508 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 14687 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. Installation Procedure 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer, Envoy, Bravada) Window Weatherstrip Run Channel Assembly Replacement - Rear (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. Page 14850 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10752 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: Customer Interest Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 7946 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 1796 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 15740 Cornering Lamp: Connector Views Cornering Lamp - Right Cornering Lamp - Left Page 9003 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Page 14759 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 15110 Electrical Symbols Part 1 Page 9399 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 4621 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 1875 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 1758 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5237 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14 Alarm Module: Service and Repair Theft Deterrent Module Replacement THEFT DETERRENT - IMMOBILIZER THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the upper and lower trim covers. 3. Remove the lock cylinder. 4. Disconnect the connector from the theft deterrent control module. 5. If necessary, disconnect the connector from the ignition lock cylinder case (1). 6. Remove the theft deterrent control module (2) from ignition lock cylinder case assembly (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2) onto the ignition lock cylinder case assembly (1). CAUTION: Refer to SIR Inflator Module Coil Caution in Service Precautions. 2. Connect the connector to the theft deterrent control module. 3. If necessary, connect the connector to the ignition lock cylinder case. 4. Install the lock cylinder. Page 4973 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 15493 Electrical Symbols Part 5 Page 5336 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 14283 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Lumbar Adjuster Switch - Passenger(W/Memory Seat) Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 4542 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, remove the BCM (1) from the rear electrical center. Page 5532 2. Remove the fuel pump relay from Junction Block # 2. 3. Start the engine and let it run until it stalls. 4. Turn the ignition key and crank the engine an additional 3 seconds to ensure that the fuel pressure has been relieved. 5. Turn the ignition to the OFF position. 6. Disconnect the negative battery cable. 7. Raise the vehicle on a suitable hoist. 8. Clean all of the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Important: The quick connect retainers will remain on the fuel filter when the fuel pipes are disconnected in the next step. 9. Squeeze the tabs on the retainers inward and disconnect both fuel pipes from the fuel filter. 10. Remove the white retainers from the fuel filter and discard. 11. Install the new blue retainers on the fuel filter. 12. Connect both fuel pipes to the fuel filter and tug firmly on the pipes to ensure that they are fully engaged. 13. Lower the vehicle. 14. Connect the negative battery cable. 15. Install the fuel pump relay in the junction block. 16. Turn the ignition to the ON position and check for leaks. 17. Install the GM Recall Identification Label. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 12957 Front Door Weatherstrip: Service and Repair Weatherstrip Side Retainer Replacement Weatherstrip Side Retainer Replacement Removal Procedure 1. Open the front door. Remove the push pin retainers (2) from the front door sealing weatherstrip located at the base of the pillar. 2. Pull back the front door sealing weatherstrip (1) in order to expose the weatherstrip side retainer screws (2). 3. Remove the screws from the weatherstrip side retainer. 4. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer (2) to the windshield pillar. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 4391 Electrical Symbols Part 2 Page 9269 For vehicles repaired under warranty, use the table. Disclaimer Page 1480 Conversion - English/Metric Page 11272 22. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps: 23. Seat one banana plug into the other in order to short the deployment harness leads. 23. Put on a pair of shop gloves. 23.2. Disconnect the pigtail adapter from the inflator module as soon as possible. 23.3. Inspect the pigtail adaptor and the SIR deployment harness. Replace as needed. 23.4. Dispose of the deployed inflator module through normal refuse channels. 23.5. Wash hands with a mild soap. Deployment Inside Vehicle 1. Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed a useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. CAUTION: ^ Refer to SIR Inflatable Module Deployment Outside Vehicle Caution in Service Precautions. ^ Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. 2. Before you begin to remove the inflator module, turn OFF the ignition. 3. Remove the ignition key. 4. Put on safety glasses. Page 10133 Various symbols are used in order to describe different service operations. A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 3989 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 8926 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the mounting bolts from the brake caliper mounting bracket. Important: When performing the following service procedure, the front brake caliper assembly and the front brake caliper mounting bracket can be removed as an assembly. 8. Remove the brake caliper and mounting bracket assembly. Page 6206 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 2515 IMPORTANT: When adding to, or changing the engine oil, use ONLY oils of the proper quality. In countries other than the United States and Canada, it may be difficult to find engine oils that display the API STARBURST symbol certifying the oil is for use in gasoline engines. If you are unable to find engine oils displaying the API STARBURST symbol, use engine oils that meet API Service SJ and/or ACEA A1-96, ACEA A2-96, or ACEA A3-96 requirements as shown in the chart. Page 6371 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 2070 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 1879 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5743 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 15741 Cornering Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 7713 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 6541 Disclaimer Page 8855 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 5276 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 9804 C600 Page 14257 Power Seat Motor: Diagrams Seat Front Vertical Motor - Driver/Passenger Page 12871 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Page 4188 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 10198 For vehicles repaired under warranty, use the table. Disclaimer Page 15514 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 6822 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 2421 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Page 4464 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Locations Locations View - HVAC Systems - Automatic Page 3200 Intake Manifold: Specifications Intake Manifold Bolt 89 inch lbs. Page 5166 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a AWD/4WD System - Delayed Front Wheel Engagement PROM - Programmable Read Only Memory: All Technical Service Bulletins AWD/4WD System Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 3864 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6084 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 3919 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 15595 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 2287 Fuel System Diagnosis - Steps 4-11 Page 5737 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8879 9. Install the rear brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Page 12904 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Body Side Hinge Replacement - Front Door - Body Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the 4 weld locations. Page 5855 Electrical Symbols Part 2 Page 9765 C101 Part 2 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes C104 Part 1 Exhaust - Exhaust Noise/Leak Exhaust Manifold: All Technical Service Bulletins Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 700 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 5307 Electrical Symbols Part 6 Page 5216 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Interior - Power Memory Seat Inoperative Power Seat Control Module: Customer Interest Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 9491 C312 Part 2 C313 Page 11270 15. Extend the SIR deployment harness and adapter to full length from the deployment fixture. IMPORTANT: On a dual stage inflator module, both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state. 16. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3). IMPORTANT: ^ The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. ^ When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module. 17. Place a 12 V minimum or a 2 A minimum power source, i.e., vehicle battery, near the shorted end of the harness. IMPORTANT: If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may not move and the noise may have been reduced. 18. Clear the area of people. Page 13048 Page 9775 C306 C307 Part 1 Page 15712 Electrical Symbols Part 7 Page 7850 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 6453 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1717 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 3401 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 2221 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14752 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 3964 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 309 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 746 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 3998 Electrical Symbols Part 2 Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 11700 Driver/Vehicle Information Display: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 5883 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 13353 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 1333 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 10134 Conversion - English/Metric Page 15694 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 1458 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 1092 Position Sensor - Horizontal Motor (W/Memory Seat) Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 3216 Electrical Symbols Part 5 Page 10426 The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: Beneath the lower control arms, inboard from the shock absorber mounts. - Beneath the center of the front crossmember. The rear end lift points for the floor jack are at the following locations: Beneath the axle housing, inboard from the shock absorber mounts. - Beneath the axle differential. Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: Chock the wheels at the end of the vehicle opposite the end being lifted. - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame. - Beneath the front suspension crossmember. - Beneath the axle. When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter. - The brake lines. - The brake cables. - The fuel filter. - The accelerator cables. - The transmission shift cables. Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 1990 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 7628 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 1788 Electrical Symbols Part 8 Page 3451 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 11615 1. Install the battery with the positive (+) side down. Use one 3 volt, type CR2032 battery, or the equivalent. 2. Ensure that the seal is in position. 3. Align the two halves of the case together and squeeze the case closed until the tabs are fully seated. 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 4328 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 2209 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 8253 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3411 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5544 3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 9311 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12693 Radio/Audio System Schematics: Steering Wheel Controls Page 5617 Involved are certain 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles built within the VIN breakpoints shown above. Parts Information Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement in SI. 2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement in SI. 3. Replace the fuel sender assembly with the new fuel sender assembly provided in the kit. The kit does not provide a new fuel level sensor. Transfer the fuel level sensor from the old fuel sender assembly onto the new fuel sender assembly. Refer to Fuel Sender Assembly Replacement in SI. 4. Install the fuel tank. Refer to Fuel Tank Replacement in SI. Claim Information For vehicles repaired under the terms of this special coverage, submit a claim with the information shown above. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct this condition are to be submitted to the dealer prior to or by October 31, 2009. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE 1. Remove the windshield garnish molding. 2. Release the front assist handle from the headliner. Refer to Assist Handle Replacement. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). IMPORTANT: Midway through the rotation cycle, the tool will move further into the access hole. 6. Gently push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade bezel should appear to be recessed. IMPORTANT: Ensure the bezel is recessed before removing the sunshade from the headliner. 7. In order to remove the sunshade from the roof panel, carefully grab the headliner at the windshield pillar and apply downward pressure while gently rocking the sunshade. 8. Remove the inboard retainer screw. 9. Remove the inboard retainer (1) from the headliner. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 374 Locations View Testing and Inspection Mirror Memory Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Doors; Testing and Inspection. Electrical - Intermittent Interior Electrical Concerns Hazard Warning Flasher: Customer Interest Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 6130 Conversion - English/Metric Page 11280 IMPORTANT: If the vehicle is equipped with dual stage air bags, the steering wheel module and the IP module will each have 4 wires. Refer to SIR Connector End Views for determining the high and low circuits. 36. Cut the 4 SIR wires leading to the connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 37. Strip 13 mm (0.5 in) of insulation from all 4 SIR wires connector leads. 38. Cut two 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the IP module deployment harness. 39. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 40. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Strut Replacement - Liftgate Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the liftgate struts using a small flat-bladed tool. 3. Remove the upper end of the liftgate struts from the ball joint. 4. Remove the lower end of the liftgate struts from the ball joint. 5. Remove the liftgate struts from the liftgate. Installation Procedure Notice: Apply pressure only at the end of the hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Position the liftgate struts to the liftgate. 2. Install the upper end of the liftgate struts to the ball joint. Press in to place until fully seated. 3. Install the lower end of the liftgate struts to the ball joint. Press in to place until fully seated. 4. Remove the support device from the liftgate. 5. Close the liftgate. Page 3096 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter adapter. ^ Tighten the oil filter adapter to 30 Nm (22 ft. lbs.). 3. Install the oil filter. Specifications Torque Converter Cover: Specifications Converter Cover Bolt ........................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger REMOVAL PROCEDURE Page 301 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 14964 Electrical Symbols Part 3 Page 11155 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Recline the driver seat rearward to access the left center trim pillar. 1. Remove the upper portion of the left center trim pillar. 2. Disconnect the electrical connector. 3. Remove the retaining clips from the B pillar. 4. Remove the inside air temperature sensor assembly (1) from the B pillar. INSTALLATION PROCEDURE 1. Connect the electrical connector to the inside air temperature sensor assembly (1). 2. Install the inside air temperature sensor assembly (1) to the B pillar. 3. Install the retaining clips to the B pillar. 4. Install the upper portion of the left center trim pillar. Page 9807 C900 C901 Page 4290 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. Technical Service Bulletin # 07076A Date: 081105 Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. SPECIAL COVERAGE Bulletin No.: 07076A Date: November 05, 2008 Subject: 07076A - SPECIAL COVERAGE ADJUSTMENT - FUEL TANK MODULAR RESERVOIR ASSEMBLY CORROSION Models Supercede: The ending breakpoints for the 2002 Chevrolet TrailBlazer and the 2003 Chevrolet TrailBlazer EXT have been revised. Please discard all copies of bulletin 07076, issued September 2008. Condition Page 5397 Fuel System Diagnosis - Steps 18-22 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, then an internal loss of pressure is indicated. 7. This step inspects the fuel pressure regulator for a fuel leak from the atmospheric vent. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 8. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 9. This step tests for a leaking fuel injector or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 12. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 14. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 16. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Page 11925 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 2415 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: Check the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. ^ Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 14336 Disclaimer Page 11174 Low Pressure Sensor / Switch: Locations Locations View - HVAC Systems - Manual Page 12536 Page 14842 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 10276 Control Arm: Service and Repair Rear Suspension Rear Axle Upper Control Arm Replacement Rear Axle Upper Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheelhouse panel. 4. Raise and support the rear axle at the designed D - height. 5. If equipped with air suspension, Repressurize the air suspension system. 6. If equipped with air suspension, disconnect the air suspension leveling sensor link from the rear axle upper control arm. 7. Remove the rear axle upper control arm to axle mounting bolt and nut. Page 4635 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Locations Page 13628 Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Front (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Body Side Window - Rear (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure Page 2193 Electrical Symbols Part 2 Page 12257 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 7036 Disclaimer Page 7492 prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or bunching, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Page 14954 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) The Driver Information Center (DIC) consists of a single line 22 character Vacuum Fluorescent (VF) display placed in the lower center area of the Instrument Panel Cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver, The display parameters are cycled, changed, and acknowledged using four (4) DIC buttons. ^ Trip Information Button representation icon appears as a road to the horizon. ^ Fuel Information Button representation icon appears as a gasoline pump. ^ Personalization Button representation icon appears as a human next to vehicle. ^ Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest): ^ Service Diagnostics ^ Driver Identifier ^ Feature Programming ^ Driver Warnings ^ Vehicle Information Vehicle Information Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC Trip Information/Reset Capabilities The available DIC Trip Information and reset capabilities are as follows: ^ Odometer - Cannot be reset ^ Trip Odometer A - Can be reset ^ Trip Odometer B - Can be reset ^ Timer - Can be reset Trip Reset Stem The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the reset stem or SWC Select button is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: ^ Odometer ^ Trip A odometer ^ Trip B odometer 2. Holding the reset stem for greater than 3 seconds or depressing the SWC Select button while either Trip A or Trip B odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip odometer parameter is being displayed, pressing the DIC Trip Information button will display the next trip odometer parameter. 4. If the next Trip Information parameter to be displayed is Timer or blank, pressing the reset stem will return the display to the Odometer. Odometer The odometer is capable of displaying values from 0 to 999,999 MI or KM. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. Trip Odometers The DIC can display Trip A or Trip B odometers. The trip odometers are capable of displaying values from 0 to 9999.9 MI or KM. When the maximum value is reached, the trip odometer will roll over to 0.0. Timer The Timer is displayed as XX (hours): XX (minutes): XX (seconds). The Timer is started and stopped using the DIC Select button. Page 15770 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 11859 Parts Information Page 3116 4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission mounting surface. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan side bolts to 25 Nm (18 ft. lbs.). ^ Tighten the oil pan end bolts to 10 Nm (89 inch lbs.). 6. Install the 4 transmission bell housing bolts that attach to the oil pan. ^ Tighten bolts to 47 Nm (35 ft. lbs.). 7. Install the A/C compressor 2 bottom bolts (4). ^ Tighten all 4 bolts to 50 Nm (37 ft. lbs.). 8. Install the front differential bolts. ^ Tighten the front differential bolts to 85 Nm (63 ft. lbs.). 9. Install the front drive axle, clutch fork assembly. Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 2926 Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly or damage to the cylinder bore sleeve will occur. 8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100). 9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch (1.6 mm) of the cylinder bore sleeve above the surface of the cylinder block. 10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN assembly to 102 Nm (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface. Page 6228 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2179 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Page 10984 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor discharge hose nut. Tighten Tighten the hose nut to 28 N.m (21 lb ft). 4. Install the compressor suction hose to the stud on the engine. 5. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor suction hose to the engine lift bracket. 7. Install the bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). 8. Connect the compressor suction hose (1) to the accumulator. 9. Install the compressor suction hose nut to the accumulator. Page 244 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 5462 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 49 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 4804 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 4800 Conversion - English/Metric Page 1095 Position Sensor - Horizontal Motor (W/Memory Seat) Position Sensor - Recline Motor (W/Memory Seat) Page 12960 Front Door Weatherstrip: Service and Repair Auxiliary REMOVAL PROCEDURE 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet Trailblazer, Envoy, and Bravada TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater Inlet hoses. Trailblazer, Envoy, and Bravada Auxiliary Blower Motor: Service and Repair Trailblazer, Envoy, and Bravada BLOWER MOTOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary assembly. 2. Disconnect the electrical connectors (4) from the blower motor-auxiliary (3). 3. Remove the air outlet duct from the blower motor-auxiliary. 4. Remove the screws (2,5) from the blower motor-auxiliary. 5. Remove the blower motor-auxiliary (3). INSTALLATION PROCEDURE 1. Install the blower motor-auxiliary (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws (2,5) to the blower motor-auxiliary. Tighten Tighten the screws to 10 N.m (88 lb in). 3. Install the air outlet duct to the blower motor-auxiliary. 4. Connect the electrical connectors (4) to the blower motor-auxiliary (3). 5. Install the HVAC module assembly. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 7690 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 4972 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5055 Conversion - English/Metric Page 11482 Page 1751 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 2387 Disclaimer Page 228 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 14330 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: Customer Interest HomeLink(R) Transmitter - Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Page 6768 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 13011 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 9535 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1710 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 6417 Page 3856 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 14106 1. Remove the plastic cover from the side rail front corner (2) and inspect the attaching bolt (1) for being overtightened. If the bolt is overtightened, it will appear to be partially recessed into the plastic mounting surface. 2. If this condition is found, remove the bolt and install a flat washer (3), P/N 120385 or equivalent, on the attaching bolt. 3. Install the bolt and washer. Tighten Tighten the bolt to 5 N.m (44 lb in). Part number 120385 is a flat washer with an outside diameter of 14 mm (9/16 in), a hole diameter of 6.5 mm (1/4 in), and a thickness of 1.2 mm (3/64 in). If using an equivalent washer, be sure it has adequate corrosion protection. Correction # 2 Position the rear cross bow (1) at the very rear of the side rails as shown. Position the front cross bow (2) in the middle (3) of the second door (4) opening. Page 1376 Turn Signal/Multifunction Switch C4 Page 11575 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Page 1334 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 4086 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10628 Locations View - HVAC Systems - Manual Page 9783 Multiple Junction Connector: Diagrams C100 C100 Page 15342 Electrical Symbols Part 3 Page 775 Engine Control Module: Service and Repair Powertrain Control Module Programming and Setup BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel - Interior lights - Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. - Heating, ventilation, and air conditioning (HVAC) systems - Engine Cooling fans etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. Do NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. - All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2(TM) to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2(TM), select Service Programming. 6. Identify vehicle information as requested by the Tech 2(TM) 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline(TM) terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2(TM) and disconnect the Tech 2(TM) from the vehicle 12. Turn OFF the ignition. 13. Connect the Tech 2(TM) to the Techline(TM) terminal. 14. Select Service Programming. 15. Select Tech 2(TM) as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. - Normal-This type of programming is for updating an existing calibration or programming a new controller. - Vehicle configuration Index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline(TM) terminal. Observe, you will need to contact the Techline(TM) Customer Support center to use this option. - Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2(TM). 23. After the download is complete, turn OFF the Tech 2(TM). 24. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 25. Install the Tech 2(TM) to the data link connector (DLC). 26. Turn ON the Tech 2(TM). 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Page 8521 Disclaimer Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 1464 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 5671 Electrical Symbols Part 1 Transfer Case Shift Control Module C1 Page 6825 Case: Specifications Case Extension to Case Bolt .................................................................................................................................................... 42.0-48.0 Nm (31-35 ft. lbs.) Case Extension to Case Bolt (4WD Shipping) ..................................................................................................................... 11.2-22.6 Nm (8.3-16.7 ft. lbs.) Page 11261 Locations View Page 5495 Fuel Injector Balance Test With Special Tool - Steps 1-5 Engine Controls - Hesitation/Idle Fluctuation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Idle Fluctuation Bulletin No.: 03-06-04-018A Date: December 08, 2003 TECHNICAL Subject: Cold Idle Fluctuation at Altitude, Hesitation on Acceleration or 1-2 Upshift Delay (Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VINs - RPO LL8) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 03-06-04-018 (Section 06-Engine). Condition Some customers may comment on one of the following conditions: - Idle fluctuation for a few seconds on the first start up after an overnight soak at higher altitudes. - Hesitation on acceleration, this typically occurs with engine coolant temperatures between 60-80°C (140-175°F). - 1-2 upshift delay at throttle openings of 25% or less and ECT between 7-30°C (45-85°F). Cause The existing PCM calibration may not be optimized for all conditions. Correction Reprogram the PCM with the latest service calibration available from Techline. The Calibrations are electronic calibrations and are NOT available from GMSPO. Calibrations were available from Techline starting February 22, 2003, on the TIS 2000 version 2.5 for 2003 data update or later. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3754 Heat Shield: Service and Repair Exhaust Muffler Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the catalytic converter heat shield rear 2 bolts where the catalytic converter heat shield connects to the muffler heat shield. 3. Remove the remaining exhaust muffler heat shield bolts and remove the heat shield from the floor panel studs. Installation Procedure 1. Install the muffler heat shield to the floor panel studs placing the muffler heat shield under the rear part of the converter heat shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure the muffler heat shield with 5 bolts. ^ Tighten the exhaust muffler heat shield bolts to 7 Nm (62 inch lbs.). 3. Lower the vehicle. Page 819 Various symbols are used in order to describe different service operations. Page 14526 Seat Adjuster Switch - Passenger (W/O Memory Seat) Page 13589 30. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 31. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner Coupling Replacement - Antenna Inner and Coupling Replacement - Antenna Outer and install the left inboard sunshade retaining clip (5). 4. Install the right rear push pin (2) 5. Install the left rear push pin (3). 6. Install the assist handles to the roof panel. 7. Connect the electrical connector to the cellular phone antenna. 8. Install the coat hooks to the roof panel. 9. Install the upper rear quarter trim panels. 10. Connect the navigation antenna electrical connector, if equipped. 11. Connect the rain sensor electrical connector, if equipped. 12. Connect the inside rear view mirror electrical connector (6). 13. If the vehicle is NOT equipped with a sunroof, seat the 2 interlocking strips (1). Page 11266 INSTALLATION PROCEDURE 1. Connect the SIR wiring harness to the module. NOTE: Refer to Fastener Notices in Service Precautions. 2. Install the inflatable side impact module to the seat back frame with the 2 screws (1). Tighten Tighten the screws to 9 N.m (80 lb in). 3. Install the top of the seat belt retractor assembly to the seat back frame with the plastic push pin (2). 4. Install the front seat back panel. 5. Install the seat back cover and pad. 6. Install the seat trim panel. 7. Install the seat assembly to the vehicle. 8. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 2328 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 15163 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil pressure switch. ^ Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 1537 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15546 Page 389 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 15598 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15341 Electrical Symbols Part 2 Page 10610 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Lumbar Adjuster Switch - Driver (W/Memory Seat) Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Driver Information Center - Setting Language Options Driver/Vehicle Information Display: All Technical Service Bulletins Driver Information Center Setting Language Options File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-015 Date: October, 2001 INFORMATION Subject: Understanding Driver Information Center Personalization/Language Options Models: 2002 Chevrolet and GMC SIT Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Driver Information Center Display (RPO U68) The Driver Information Center (DIC) display on the instrument cluster has a multi-lingual capability. A vehicle owner may accidentally put the DIC into a language he or she does not understand. This may make it difficult or impossible for the owner to figure out how to get the display back to the preferred language. This difficulty is resulting in clusters being replaced at the dealer as a warranty return. Dealers should reset the DIC back to the language that the owner understands by following these steps: 1. Press and hold the personalization button (2) and the trip information button (1) at the same time. The DIC will begin scrolling through the languages. Each language will be shown in that particular language (English will be in English, French will be in French, etc.). 2. When the preferred language appears, release both buttons. The DIC will then display the information in the language that was selected. Page 5731 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15340 Electrical Symbols Part 1 Page 3126 Electrical Symbols Part 5 Page 1874 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 15990 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 15300 Electrical Symbols Part 2 Page 4787 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft: Customer Interest Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 7442 Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Page 13576 28. Disconnect the inside rear view mirror electrical connector (6). 29. Disconnect the rain sensor electrical connector, if equipped. 30. Disconnect the navigation antenna electrical connector, if equipped. 31. Remove the upper rear quarter trim panels. 32. Remove the coat hooks from the roof panel. 33. Disconnect the radio control module electrical connector from the right body side window. 34. Disconnect the radio antenna module electrical connector from the left body side window. 35. Disconnect the electrical connector from the cellular phone antenna. 36. Remove the 2 push pins from the rear of the headliner. 37. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 38. Fully recline the bucket seats. 39. With the aid of an assistant, release the interlocking strips (1) that retain the headliner to the roof panel. 40. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 41. With the aid of an assistant, remove the headliner from the vehicle. INSTALLATION PROCEDURE Page 14117 1. Remove the plastic cover from the side rail front corner (2) and inspect the attaching bolt (1) for being overtightened. If the bolt is overtightened, it will appear to be partially recessed into the plastic mounting surface. 2. If this condition is found, remove the bolt and install a flat washer (3), P/N 120385 or equivalent, on the attaching bolt. 3. Install the bolt and washer. Tighten Tighten the bolt to 5 N.m (44 lb in). Part number 120385 is a flat washer with an outside diameter of 14 mm (9/16 in), a hole diameter of 6.5 mm (1/4 in), and a thickness of 1.2 mm (3/64 in). If using an equivalent washer, be sure it has adequate corrosion protection. Correction # 2 Position the rear cross bow (1) at the very rear of the side rails as shown. Position the front cross bow (2) in the middle (3) of the second door (4) opening. Page 2799 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation Tools Required ^ J39544-KIT Wheel Nut Torque Adapters Caution: Refer to Brake Dust Caution in Service Precautions. Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Important: Penetrating oil effectively removes tight wheels. Apply the oil sparingly to the hub surface, if you use oil. Removing wheels can be difficult, because of foreign material or a tight fit between the wheel center hole and the hub or the rotor.Excessive force, such as hammering on the wheel or the tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. Wheel removal should be performed in the following manner: 1. Tighten all wheel nuts on the affected wheel. Do not torque the wheel nuts. 2. Loosen each wheel nut two turns. 3. Apply quick, hard jabs to the brake pedal in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle from side to side, using the body weight of 1 or more persons. 4. Repeat this procedure if the wheel is still tight. Removal Procedure 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel hub cap, if equipped. 3. Remove the wheel nuts. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly. 5. Clean the wheel nuts, studs, and the wheel and rotor mounting surfaces. Installation Procedure Page 1424 Equivalents - Decimal And Metric Part 1 Page 4225 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 15563 For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a Campaign Initiation Detail Report. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 9419 For vehicles repaired under warranty, use the table. Disclaimer Page 5515 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday - Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 6302 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 12438 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 3085 Engine Oil: Description and Operation Api Oil and Additives WHAT KIND OF ENGINE OIL TO USE Oils recommended for your vehicle can be identified by looking for the starburst symbol. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Do not use any oil which does not carry this starburst symbol. If you choose to perform the engine oil change service yourself, be sure the oil you use has the starburst symbol on the front of the oil container. If you have your oil changed for you, be sure the oil put into your engine is American Petroleum Institute certified for gasoline engines. You should also use the proper viscosity oil for your vehicle, as shown in the viscosity chart. As in the chart shown previously, SAE 5W-30 is the only viscosity grade recommended for your vehicle. You should look for and use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If you cannot find such SAE 5W-30 oils, you can use an SAE 10W-30 oil which has the API Starburst symbol, if it's going to be 0°F (-18°C) or above. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. NOTICE: Use only engine oil with the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Don't add anything to your oil. The recommended oils with the starburst symbol are all you will need for good performance and engine protection. Page 4992 Equivalents - Decimal And Metric Part 1 Locations Locations View Page 4156 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 416 Front Passenger Door Module (FPDM) C2 Page 15160 DISCLAIMER Page 4213 Page 15567 Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Page 11125 Ambient Temperature Sensor / Switch HVAC: Locations Locations View - HVAC Systems - Automatic Page 1518 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5635 9. Use the following procedure with two wheel drive (2WD): 9.1. Remove the fuel bundle retaining bolt (3) from the transmission. 9.2. Disengage the fuel bundle from the clip at the rear of the transmission. 10. Use the following procedure with four wheel drive (4WD): 10.1. Remove the fuel bundle retaining bolt (3) from the transmission. 10.2. Remove the fuel bundle from the clip at the rear of the transmission. 11. Disconnect the EVAP purge pipe (2) from the EVAP canister (1). Page 6606 For vehicles repaired under warranty, use the table. Disclaimer Page 6859 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 11813 Page 4575 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 14626 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 7426 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 148 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 14856 Various symbols are used in order to describe different service operations. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11562 Disclaimer Page 4345 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14733 Electrical Symbols Part 2 Brakes - Revised Caliper Mounting Bolt Torque Spec. Brake Caliper: Technical Service Bulletins Brakes - Revised Caliper Mounting Bolt Torque Spec. Bulletin No.: 03-05-23-002A Date: April 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Brake Caliper Bracket Mounting Bolt Fastener Tightening Specification Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2004-2005 Chevrolet SSR 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add models, model years and update the fastener tightening specification. Please discard Corporate Bulletin Number 03-05-23-002 (Section 05 - Brakes). This bulletin is being issued to revise the front brake caliper bracket mounting bolt fastener tightening specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct fastener tightening specification for the front brake caliper bracket mounting bolt is 150 N.m (110 lb ft). Disclaimer Page 9372 Fuse Block - Underhood C3 Page 13710 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 9307 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14634 Disclaimer Page 8876 6. Remove the front brake pads from the mounting bracket. 7. Inspect the brake hardware. 8. Remove the brake pad retaining clips from the mounting bracket. 9. Remove the brake caliper mounting bracket retaining bolts. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 3920 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 7829 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Service and Repair Thermostat: Service and Repair Thermostat Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the necessary coolant from the radiator. 2. Loosen the outlet hose clamp at the water inlet (1) of the thermostat. Remove the outlet hose from the water inlet. 3. Remove the thermostat housing at the water inlet bolts. 4. Remove the thermostat housing from the engine block. 5. Clean all of the surfaces of the thermostat housing. 6. Clean the sealing surface of the engine block. Installation Procedure Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 5985 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 11678 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 15471 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 10638 Defrost Actuator Mode Actuator Page 5893 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Page 3675 Electrical Symbols Part 4 Page 3972 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8881 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). 7. Install the boot seals into the caliper housing bores using the J 8092 and the J 43885. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions Service and Repair Map Light Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Carefully grasp the sides of the lens to partially expose the rear retaining tab. 2. Use a flat bladed tool in order to release the rear lens retaining tab. 3. Lower the rear edge of the lens away from the headliner. 4. Move the lens rearward in order to release the front horizontal retaining tab. 5. Remove the lens from the headliner. Page 4154 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5724 Electrical Symbols Part 2 Page 870 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 4780 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 3907 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8902 1. Install the brake pad retaining clips on the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. Important: Ensure that the retaining clip for the brake pads is properly seated in the brake caliper. 3. Install the retaining clip from the brake caliper. Page 3924 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 15616 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 12151 Speaker: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 9459 C201 Part 2 Page 14517 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Page 5479 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Specifications Fuel Level Specifications Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. A/T, Exhaust - Rattling Noise From Under the Vehicle Transmission Cooler: All Technical Service Bulletins A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1535 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5830 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Locations Page 5040 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Part 1 Turn Signal/Multifunction Switch C1 Part 2 Page 4585 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 392 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 15515 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13699 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Audio System - Whine/Buzz Noise on Acceleration Technical Service Bulletin # 02-08-44-016A Date: 021201 Audio System - Whine/Buzz Noise on Acceleration File In Section: 08 - Body and Accessories Bulletin No.: 02-08-44-016A Date: December, 2002 TECHNICAL Subject: Whine, Buzz, Generator Whine, Whine Type Noise Heard on Acceleration (Repair Vehicle Sound System Wiring) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to December, 2001 This bulletin is being revised to change the model year. Please discard Corporate Bulletin Number 02-08-44-016 (Section 08 - Body and Accessories). Condition Some customers may comment on a buzzing or generator whine-type noise that emanates from the vehicle speakers with the radio on or off and when the headlights are on. This sound may be altered by changing the IP backlighting intensity (Dimming Function). Or, a noise emanates from the All-Wheel Drive system (if equipped), of 1 to 2 seconds duration during initial acceleration, at 24 km/h (15 mph) or at 48 km/h (30 mph). The generator whine-type noise may be observed at any time, however it is more noticeable when the electrical load on the system is high. Cause The cause of this condition may be EMI interference that is being transmitted to the radio system speakers from within the body wiring harness. Correction To determine which parts to order, you will need to inspect the vehicle. There are four types of audio systems available and three specific service wiring harness assemblies. ^ Bose(R) Premium Sound System with Rear Audio Controls ^ Bose(R) Premium Sound System without Rear Audio Controls ^ Non-Bose(R) Sound System with Rear Audio Controls ^ Non-Bose(R) Sound System without Rear Audio Controls See the Parts Information below for applicable part numbers. Parts Information Paris are currently available from GMSPO. Warranty Information Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. Technical Service Bulletin # 07076A Date: 081105 Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. SPECIAL COVERAGE Bulletin No.: 07076A Date: November 05, 2008 Subject: 07076A - SPECIAL COVERAGE ADJUSTMENT - FUEL TANK MODULAR RESERVOIR ASSEMBLY CORROSION Models Supercede: The ending breakpoints for the 2002 Chevrolet TrailBlazer and the 2003 Chevrolet TrailBlazer EXT have been revised. Please discard all copies of bulletin 07076, issued September 2008. Condition Page 9901 38. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 39. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 40. Reinstall the rear electrical center cover. 41. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate, and install the retainers. 42. Reinstall the knee bolster (TrailBlazer). 43. Reinstall the left side closeout/insulator panel (TrailBlazer). 44. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 45. Reinstall the console to the vehicle and install the retainers. 46. Reinstall the shift boot and handle assembly. 47. Reinstall the console bin and retainers. 48. Reinstall the first lock pillar trim and carpet retainers to both door openin9s. 49. Position the drivers seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 50. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 51. Connect the Tech 2(R) and clear codes. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 3707 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 4183 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Locations Locations View Page 3272 2. Use the J 44218 to install the front oil seal. 3. Remove the J44218. 4. Install the crank balancer shaft. Page 4963 Electrical Symbols Part 2 AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 12236 Page 14899 DISCLAIMER Page 4799 Various symbols are used in order to describe different service operations. Page 4338 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 246 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 472 Power Seat Control Module: Description and Operation MEMORY SEAT MODULE (DSM) Battery positive voltage is supplied through the seat circuit breaker to the DSM. In response to a valid manual or memory switch command, the DSM will apply power and ground to the selected motors within 150 ms. To limit peak power, DSM restricts the number of motors that can be turned on simultaneously to three motors. If the module detects all four switches at the same time, DSM turns on three seat adjusters: horizontal, front, and rear. If the user continues to hold all four switches, the DSM actuates the fourth motor only after one of the first three motors has reached its end motion. For a memory recall operation, the DSM first moves the horizontal, front, and rear motors first. If all four switches are still activated, DSM actuate the recline motor only when one of the seat adjusters has reached its end motion. In order to conserve battery power, the DSM enters automatic standby mode whenever the unit has been inactive for 16 seconds. In the standby mode, the DSM stores memory settings so that when it is awake again it knows where the seat is set. Page 15453 Electrical Symbols Part 6 Page 7830 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 9561 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 10103 Electrical Symbols Part 3 Page 4782 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 10334 1. Install the stabilizer shaft link and the washer to the lower control arm. 2. Install the stabilizer shaft link to lower control arm retaining nut. 3. Install the stabilizer shaft link to the stabilizer shah. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer shaft link to stabilizer shaft retaining nut. Tighten the stabilizer shaft retaining nuts to 100 Nm (74 ft. lbs.). 5. Lower the vehicle. Engine - Redesigned Oil Pick-Up and Front Cover Timing Cover: Technical Service Bulletins Engine - Redesigned Oil Pick-Up and Front Cover Bulletin No.: 04-06-01-015 Date:May 24, 2004 INFORMATION Subject: New Design Oil Pick Up Tube and Front Cover Models: 2004 Buick Rainier 2002-2004 Chevrolet Trailblazer 2002-2004 GMC Envoy 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Page 12571 Page 5287 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 9894 With the new harness stretched out on a work surface, you will find two multi-terminal breakouts midway down the harness. You will need to trim these wire breakouts from the harness by cutting the four wires below at both locations as close to the taped portion of the harness as possible. ^ The Brown wire ^ The Brown/White wire ^ The Black wire ^ The Blue wire What you will end up with is a new harness with two green connectors on one end and four terminals on the other end. 27. Position the new radio speaker wiring harness to the vehicle. The small green connectors go to the upper IP speakers. 28. With the green connectors in hand, insert the new wiring harness from under the IP up to the radio area of the IP where the radio is normally positioned. 29. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 30. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 31. Disconnect the mechanics wire from the speaker wires. Connect the speaker wires to the speaker and fasten the speaker to the IP. 32. Repeat the last three steps for the right speaker. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting. 35. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 36. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 37. Route the new harness under the carpet from the rear of the console to the 8-way connector. 38. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 39. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 40. Reposition the rear electrical center through the carpet and reposition the carpet. 41. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 42. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). Locations Locations View Page 7336 7. Install the inner axle to the front drive axle. Refer to Inner Axle Shaft Replacement-Front Drive Axle. 8. Install the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System. 9. Remove the left and right front wheel drive shafts from the frame. 10. Remove the left, right shock module and steering knuckles from their supports. 11. Install the right and left front wheel drive shafts to the front drive axle. 12. Install the vent hose to the front drive axle. 13. Install the left and right shock modules to the frame. 14. Install the upper shock module retaining nuts. Tighten Tighten the upper shock module mounting bolts to 100 N.m (74 lb ft). 15. Install the steering knuckle to the upper control arm. 16. Install the upper ball joint pinch bolt and nut. Tighten Tighten the upper shock module mounting bolts to 40 N.m (30 lb ft). Page 15526 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Page 5212 Electrical Symbols Part 5 Page 1703 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 14385 5. Pull the seat back cover down approximately 18 cm (7 in) from the top of the seat back, leaving the reinforcement bar exposed. 6. Install the hog rings that retain the seat back pad to the reinforcement bar. 7. Pull the seat cover over the seat back pad. 8. Press the seat cover hook and loop retaining strips together by firmly running your hand over the seat back cover. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the seat belt bezel to the top of the seat back with the mounting screw. Tighten Tighten the seat belt bezel screw to 3 N.m (26 lb in). Page 10096 6. Slide the shock dampener (1)over the inner tie rod housing (2) until the front lip of the shock dampener (1) bottoms against the inner tie rod housing (2). 7. Slide the shock dampener (3) forward onto the rack (2). Important: Threads must be clean prior to LOCTITE application. Check the LOCTITE (or equivalent) container expiration date. Use only enough LOCTITE to evenly coat threads. 8. Apply LOCTITE 262 (or equivalent) to the inner tie rod (1) threads. 9. Attach the inner tie rod (1) onto the rack (2). Important: The pipe wrench must be placed at the valve end of the steering gear (5) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (5). 10. Maintain the pipe wrench on the opposite end of the rack (5) next to the inner tie rod housing. 11. Place a torque wrench and J34028 on the flats of the inner tie rod housing (1). Tighten the inner tie rod housing to 100 Nm (74 ft. lbs.). 12. Slide the shock dampener (1)over the inner tie rod housing (2) until the front lip of the shock dampener (1) bottoms against the inner tie rod housing (2). 13. Remove the gear from the vise. 14. Install the rack and pinion boot. Page 3676 Electrical Symbols Part 5 Page 5068 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Page 4862 Electrical Symbols Part 6 Page 11490 5. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the bolt to 70 N.m (52 lb ft). Page 5308 Electrical Symbols Part 7 Page 10779 Blower Motor Switch - Front Auxiliary Page 52 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 9384 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 5022 Electrical Symbols Part 1 Page 3695 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 1941 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 5248 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 7107 Disclaimer Page 2288 Fuel System Diagnosis - Steps 12-17 Page 13872 Disclaimer Page 8359 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 8927 9. Remove the retaining clips from the brake rotor. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Important: if the brake rotor is not going to be replaced but just removed from the front hub, mark the relationship of the brake rotor and a wheel stud. 10. Remove the front brake rotor from the wheel hub. 11. Using the J 42450-A, clean the brake rotor contact area on the front hub. Installation Procedure Important: Ensure that the relationship marks on the brake rotor and the wheel stud are aligned before installing the brake rotor. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 7272 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 5825 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 274 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 6950 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Page 14973 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 10393 Tighten Tighten the shock module yoke to lower control arm retaining nut to 110 N.m (81 lb ft). Install the tire and wheel. Refer to Tire and Wheel Removal and Installation. Lower the vehicle. Disclaimer Page 12677 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Front Suspension Spring ( Coil / Leaf ): Service and Repair Front "For information regarding this component please refer to shock absorber service and repair" Rear Oil Seal and/or Bearing Replacement Axle Bearing: Service and Repair Rear Oil Seal and/or Bearing Replacement Rear Oil Seal and/or Bearing Replacement ^ Tools Required J 8092 Universal Driver Handle- 3/4 in - 10 - J 21128Axle Pinion Oil Seal Installer - J 23690 Bearing Installer - J 2619-01 Slide Hammer - J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover and the gasket. 4. Remove the axle shaft. 5. Remove the axle shaft seal and/or the bearing from the axle housing using the J 44685 (1) and the J2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 5203 Disclaimer Page 14904 Disclaimer Page 11645 DISCLAIMER Page 10330 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1131 Sunroof Switch Page 11186 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Page 7298 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. Page 2804 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Tools Required ^ J8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J8001 to a stand. 3. Ensure that the J8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Page 11801 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 8971 9. Install the rear brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Page 5115 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 13568 INSTALLATION PROCEDURE 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner and ensure that the retaining strips (1) are engaged, and the headliner harnesses (4) hang free of the headliner. 4. Install the assist handles to the roof panel. 5. Install the right rear push pin (2) 6. Install the left rear push pin (3). 7. Install the sunshades to the headliner. 8. Install the left and right sunshade retaining clips (5). Tighten Tighten the sunshade retaining clip screws to 10 N.m (88 lb in). Communication Module - Revised Service Procedure Central Control Module: Technical Service Bulletins Communication Module - Revised Service Procedure File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-012 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised Communication Interface Module Replacement Reconfiguration Procedure Models: 2002 Buick Century, LeSabre, Regal 2002 Cadillac DeVille, Seville 2002 Chevrolet Impala, Monte Carlo, TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Aurora, Bravada, Intrigue 2002 Pontiac Bonneville with Generation 4 On Star(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the Communication Interface Module Replacement procedure in the Cellular Communications sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 4 (formerly F1) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool. Important: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 1. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. 2. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 3. Use the ID information menu on the scan tool to access the new Station ID (STID) and the electronic serial number (ESN) and from the new VCIM. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VCIM and ask the advisor to perform the following procedure: 5. Add the new STID and the ESN to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 7738 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 15319 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 2671 Oil Change Reminder Lamp: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 12327 Page 7163 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 3027 Drive Belt Falls Off Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Page 14062 Memory Seat Module - Passenger C4 Page 15782 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 10106 Electrical Symbols Part 6 Electrical - No Start/Multiple Systems Inoperative Driver/Vehicle Information Display: All Technical Service Bulletins Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 7526 Disclaimer Page 5971 Electrical Symbols Part 1 Page 12945 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 1753 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 14782 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 15913 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 396 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 5486 Conversion - English/Metric Page 5866 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 10191 For vehicles repaired under warranty, use the table. Disclaimer Page 3287 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 4679 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5695 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 15682 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 11498 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the nut (1) securing the retractor assembly (2) to the seat back frame. Tighten Tighten the center seat belt retractor mounting nut to 55 N.m (40 lb ft). 2. Install the seat belt bracket (1) to the seat back frame with the 2 bolts (2). Tighten Tighten the rear seat belt bracket mounting bolts to 35 N.m (26 lb ft). 3. Install the seat back cover and pad to the seat back. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 4699 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 9381 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 8352 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 5655 Fuel Pump And Sender Assembly Page 10741 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1786 Electrical Symbols Part 6 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 12573 Labor Time Information Page 8289 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2273 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Page 15403 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 6300 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 6255 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11072 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 13406 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the steering gear crossmember mounting bolts. Tighten the steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the lower control arm to frame mounting bolts. Tighten the lower control arm to frame mounting bolts to 265 N.m (196 lb ft). 4. Install the engine shield. 5. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 6. Lower the vehicle. Page 5271 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 14243 Memory Seat Module - Passenger C2 Page 15509 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12592 Navigation Module: Service and Repair Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Fold and tumble the right rear seat to a cargo position. 2. Leaving the electrical connectors attached, remove the communication interface module from the Vehicle Communication Interface Module (VCIM) bracket. Refer to Communication Interface Module Replacement (Trailblazer, Envoy, Bravada) or Communication Interface Module Replacement (Trailblazer EXT, Envoy XL) in Interior Trim. 3. Using a flat bladed tool, release the retaining tab (1) on the VCIM bracket. 4. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 5. Remove the VCIM bracket from vehicle. 6. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 7. Remove the VCIM bracket from vehicle. INSTALLATION PROCEDURE Page 8990 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Blower Motor Control Processor Replacement Control Module HVAC: Service and Repair Blower Motor Control Processor Replacement REMOVAL PROCEDURE 1. Remove the right closeout panel. 2. Disconnect the electrical connector from the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor mounting screws (1). 5. Remove the blower motor control processor (2:). INSTALLATION PROCEDURE 1. Install the blower motor control processor (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor mounting screws (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector to the blower motor. 5. Install the right closeout panel. A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Rearview Mirrors (Outside) - Uncommanded Movement Door Module: All Technical Service Bulletins Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 4455 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The tender to radiator support rod will be removed as part of the radiator support cover. 1. Remove the radiator support cover. 2. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator. 3. Remove the air cleaner element (1) by grasping the filter and removing it from the air cleaner outlet duct (2) with a twisting and pulling motion. 4. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 1625 Conversion - English/Metric Page 4697 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 3883 Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM mounting studs (1) to the intake manifold, if necessary. Tighten Tighten the studs to 6 N.m (53 lb in). Install the PCM (2) to the intake manifold. 2. Install the PCM mounting nuts and bolts (3). Tighten Tighten the nuts and bolts to 10 N.m (89 lb in). 3. Install the PCM harness connectors (3) to the PCM (2). 4. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 5. If a new PCM is being installed, the PCM must be programmed. See: Testing and Inspection/Programming and Relearning Page 3692 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 8089 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 2203 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 5841 Conversion - English/Metric Steering Gear Crossmember Replacement - Front Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Front Steering Gear Crossmember Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. 4. Remove the lower control arm to frame mounting bolts. 5. Remove the steering gear crossmember mounting bolts. 6. Remove the steering gear crossmember. Installation Procedure 1. Install the steering gear crossmember. Page 15325 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 5738 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 3028 Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Page 1107 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Lumbar Adjuster Switch - Passenger(W/Memory Seat) Page 6105 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10684 Air Duct: Service and Repair Air Distribution Ducts Replacement - Auxiliary (Upper) REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the headliner. 3. Remove the mid upper air distribution duct retaining fastener (7). 4. Remove the mid upper air distribution duct (6) from the C-pillar. 5. Remove the lower air distribution duct (5) from the C-pillar. INSTALLATION PROCEDURE 1. Install the lower air distribution duct (5) to the C-pillar. 2. Install the lower air distribution duct retaining screw (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the lower air distribution duct retaining screw. Tighten Tighten the screw to 1.9 N.m (17 lb in). 4. Install the upper air distribution duct (6) to the C-pillar. 5. Install the upper air distribution duct retaining screw (7). Tighten Page 15049 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 7449 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Page 3746 Exhaust Manifold: Service and Repair Exhaust Manifold Heat Shield Replacement Exhaust Manifold Heat Shield Replacement Removal Procedure 1. Remove the air cleaner resonator outlet duct. 2. Remove the transmission filler tube stud nut from the A.I.R. adapter and move the filler out of the way. 3. Remove the oil level indicator tube. 4. Remove the oxygen sensor from the exhaust manifold. 5. Remove the 4 manifold heat shield nuts and remove the heat shield. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 2062 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 3217 Electrical Symbols Part 6 Page 13086 Rear Door Striker: By Symptom Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 14852 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 14268 Position Sensor - Horizontal Motor (W/Memory Seat) Page 5946 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Diagrams Engine Oil Level And Temperature Sensor Page 809 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15764 Electrical Symbols Part 6 Fuel Hose/Pipes Replacement - Filter to Engine Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Filter to Engine REMOVAL PROCEDURE CAUTION: ^ Refer to Fuel and EVAP Pipe Caution in Service Precautions. ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the powertrain control module connectors from the powertrain control module (PCM). 3. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the EVAP purge pipe (5) from the EVAP canister purge valve. 6. Disconnect the integral clip (3) from the engine bracket. 7. Remove the fuel pipe bundle from the fuel pipe clip at the rear of the engine. 8. Remove the fuel tank shield, if equipped. Page 5750 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 1386 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 995 Page 3001 9. Remove the camshafts. 10. Using a suitable adapter, apply air pressure to the cylinder. 11. Install the J 44228 and compress the valve 12. Remove the valve keys. 13. Remove the J 44228. Page 9017 5. Remove the reservoir from the brake master cylinder. 6. Remove the seals from the brake master cylinder. 7. Clean the master cylinder area with denatured alcohol, or equivalent. 8. Dry the master cylinder with non-lubricated, filtered air. Installation Procedure 1. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 bake fluid from a clean, sealed brake fluid container. 2. Install the lubricated seals, make sure that the seals are fully seated in the brake master cylinder. Page 767 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. Page 11134 Air Temperature Sensor Assembly - Inside Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Page 11112 Control Module HVAC: Locations Manual Control Locations View - HVAC Systems - Manual Page 13969 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15119 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8827 Electrical Symbols Part 2 Page 14284 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 6144 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. AWD/4WD System - Delayed Front Wheel Engagement PROM - Programmable Read Only Memory: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 2858 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test ^ Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: ^ When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. ^ When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. ^ When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. ^ When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 9797 C308 C309 (Long Wheelbase Body,Type VIN 6) Part 1 Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Specifications Transfer Case Mount: Specifications NVG126-NP4 Transmission Mount to Transmission Bolts ............................................................................................................................................. 25 Nm (18 lb ft) NVG 226-NP8 Transmission Mount to Transmission Bolts ............................................................................................................................................. 25 Nm (18 lb ft) Page 3966 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 778 Engine Control Module: Service and Repair Service Programming System (SPS) SERVICE PROGRAMMING SYSTEM (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: The Vehicle Identification Number (VIN) - The crankshaft variation learned position - The software/calibrations identification numbers - The control module security information - Flash Read Only Memory - Flash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. SERVICE PROGRAMMING METHODS The 4 methods of programming a control module and the proper tools for each method are as follows: Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle - Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. - Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle - Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle. BEFORE PROGRAMMING B CONTROL MODULE IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. - General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. - Heating, Ventilation, And Air Conditioning (HVAC) systems - Engine Cooling fans, etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. - All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Page 12499 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 6819 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Page 4041 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 13587 33. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 34. Install the right rear quarter lower trim panel. 35. Install the left rear quarter lower trim panel. 36. Install the left/right rear body side trim rear window garnish molding. 37. Install the left/right front body side window garnish molding. 38. Install the lift gate door sill plate. 39. Install the cargo tie-down loops. Tighten the cargo tie-down loop bolts to 35 N.m (26 lb ft). 40. Install the rear side door sill plates. 41. Install the second row seats. 42. Install the third row seats. 43. Install the luggage/cargo shade assembly, if equipped. 44. Install the cargo net, if equipped. Headliner Replacement (TrailBlazer, Envoy, Bravada) Headliner Replacement (TrailBlazer, Envoy, Bravada) Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the video display. 10. If equipped, remove the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement Rear. 11. Remove the sunshades from the headliner. 12. If equipped with OnStar(R), perform the following procedure: 1. Disconnect the navigation antenna cable from the communication interface module. 2. Remove the navigation antenna cable from the right side door rocker panel attachments. 3. Remove the navigation antenna cable from the right center pillar. Page 12340 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 5279 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 8094 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 13591 Rear. 24. Install the video display. 25. Install the windshield garnish moldings. 26. Install the center pillar trim panels. 27. Install the rear side door sill plates. 28. Install the front side door sill plates. 29. Install the rear seats. 30. Install the luggage/cargo shelf assembly, if equipped. 31. Install the cargo net, if equipped. Headliner Replacement - Trailblazer, Envoy, Bravada Headliner Replacement (Trailblazer, Envoy, Bravada) Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the instrument panel (IP) trim pad. 10. Open the IP compartment door and lower the door to the full down position. 11. Disconnect the coax cable (2) and the headliner harness electrical connector (1), located near the bottom of the HVAC blower motor. 12. Remove the lower rosebud (2) that fastens the headliner harness to the cowl. 13. Remove the 3 clips (1) retaining the headliner harness to the right windshield pillar. 14. Attach a mechanic's wire to the end of the headliner harness. 15. The wire harness is located in the cowl insulation access hole, behind the IP. In order to remove the wire harness, grasp the headliner harness near the bottom of the windshield and carefully pull upward. 16. Leaving the mechanic's wire positioned behind the IP, remove the headliner harness from the mechanics wire. 17. Remove the video display. 18. If equipped, remove the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement Rear. 19. Remove the sunshades from the headliner. 20. If equipped with OnStar(R), perform the following procedure: Page 4279 Electrical Symbols Part 7 Page 14060 Memory Seat Module - Passenger C2 Page 145 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 5274 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5180 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 13764 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 6471 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 4563 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9216 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 7443 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 10990 1. Install the new O-ring seal. 2. Install evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the evaporator tube to the evaporator (5). Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 6. Install the coolant recovery tank. 7. Install the washer solvent container. 8. Install the nuts (1,2) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400. Page 4880 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8158 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 15141 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 4216 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 2274 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Page 8224 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 4011 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12370 Page 4968 Electrical Symbols Part 7 Page 4151 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 10786 Air Temperature Sensor Assembly - Inside Page 4236 Electrical Symbols Part 5 Page 4720 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 12239 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 4709 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 1403 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13600 4. Ensure the top of the roof panel tab (2) is positioned over the plastic retaining tab (1). 5. Using a flat bladed tool, carefully push up on the bottom of the front roof panel tab (1) until fully seated. 6. Using a flat bladed tool, carefully push on the bottom of the rear roof panel tab until fully seated. 7. Close the bezel covers. 8. Pull downward on the assist handle to ensure the handle is fully secured to the roof panel. Page 5960 Conversion - English/Metric Page 9317 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12148 Electrical Symbols Part 6 Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 4309 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 9239 Conversion - English/Metric Page 1523 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9582 22. Remove the screws retaining the IP bezel to the IP and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the dash, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 27. With both of the green connectors and the first breakout of four wires in hand, insert the new wiring harness from under the IP up to the radio area of the IP, where the radio is normally positioned. 28. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 29. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 30. Disconnect the mechanics wire from the speaker wires, connect the speaker wires to the speaker and fasten the speaker to the IP. 31. Repeat the last three steps for the right speaker. 32. Remove the CPA from the radio connector, remove the wires shown below from the radio connector and replace them with the wires from the new wiring harness. ^ Remove wire in cavity B9 and insert the Brown wire. ^ Remove wire in cavity B8 and insert the Brown/White wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Blue wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminal from the wires you just removed from the connector. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet to the area of the rear audio control, and reposition the carpeting. 35. Remove the CPA from the rear audio control connector and remove four wires from the Rear Audio Control in-line harness connector and replace them with the wires from the new harness as listed below. ^ Remove wire in cavity B3 and insert the Brown wire. ^ Remove wire in cavity A8 and insert the Brown/White wire. ^ Remove wire in cavity A9 and insert the Blue wire. ^ Remove wire in cavity A1 and insert the Black wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires of the original harness, as close to the taped portion of the harness as possible. 36. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 37. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 38. Route the new harness under the carpet from the rear of the console to the 8-way connector. 39. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE Locations Locations View Page 7537 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 15899 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11133 Ambient Air Temperature Sensor Page 6964 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 4355 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4237 Electrical Symbols Part 6 Page 3733 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Instruments - Erratic Speedometer Operation Ground Strap: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 8875 9. Install the brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Rear Brake Caliper Bracket Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanics wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the rear brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. Page 15489 Electrical Symbols Part 1 Propshaft Speed Sensor - Front Page 3247 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 12812 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 48 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 13733 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Data Link Communications Information Bus: Description and Operation Data Link Communications CIRCUIT DESCRIPTION The Data Link Connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for Diagnostic Trouble Codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a State Of Health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the Inflatable Restraint Sensing And Diagnostic Module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Class 2 serial data at terminal 2. - Common signal ground at terminal 5. CLASS 2 SERIAL DATA LINE The class 2 serial data line on this vehicle is a ring/star configuration. The BCM and PCM form the ring portion of the class 2 serial data circuit. If one of the class 2 serial data circuits to the BCM or PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The Body Control Module (BCM) - The Driver Door Module (DDM) - The Electronic Brake Control Module (EBCM) - The Front Passenger Door Control Module (FPDM) - The HVAC control module - The inflatable restraint sensing and diagnostic module (SDM) - The Instrument Panel Cluster (IPC) - The Liftgate Control Module (LGM) - The memory seat module-driver W/power seat - The memory seat module-passenger W/power seat - The Powertrain Control Module (PCM) - The radio - The radio amplifier - The RSA/HVAC control module-rear auxiliary - The theft deterrent control module W/Immobilizer - The transfer case shift control module W/4WD - The Vehicle Communication Interface Module (VCIM) W/UE1 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via two splice packs and a data link connector (DLC): SP205 Located behind the I/P near the headlamp switch connector. - SP206 Located in the body harness near the rear of the right rear seat under the carpet. - DLC connects the scan tool to the class 2 serial data circuits. Refer to Data Link Communications Component Views. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Locations Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 462 Power Seat Control Module: Locations Locations View Page 15248 Page 15620 Brake Lamp: Description and Operation The STOP fuse in the engine wiring harness junction block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both the VEHICLE STOP fuse and the VEHICLE CHMSL fuse. The current flow is now to the stop lamps which are grounded at G401 and G402. The Center High Mounted Stop Lamp (CHMSL) is grounded at G401. For trailer wiring, a separate stop lamp circuit is connected through the GMSF to the trailer wiring harness. Specifications Valve: Specifications Valve System Stationary Lash Adjuster Hydraulic Page 811 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4142 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 5154 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14796 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4947 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 4294 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1168 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 14388 7. Remove the release latch knob. 8. Remove the screw that retains the seat back latch release bezel to the seat back. 9. Release the J strips on the bottom of the seat back frame. 10. Release the hook and loop retaining strips at the bottom of the seat back. 11. Remove 3 push-pins from the bottom of the seat back. IMPORTANT: Ensure that the hook and loop retaining strips remain attached to the seat back pad. Page 13607 1. Use a flat-bladed tool in order to release the 4 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. INSTALLATION PROCEDURE 1. Ensure that all 4 retaining tabs are securely attached to the sill plate. 2. Align the retaining tabs to the liftgate door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Page 5824 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4257 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9684 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 2318 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 4750 Location Views Page 5067 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 15333 Speedometer Head: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 2746 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 7446 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-04-19-002B Date: 040404 Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1030 4. Remove the three push-in retainers that attach the air inlet grille (leaf screen) to the plenum sheet metal. 5. Lower the hood to the secondary latch. 6. Using a suitable marker or masking tape, mark the location of both wiper blades on the windshield. 7. Remove the covers from the nuts that attach the wiper arms. 8. Remove the nuts from the wiper arms. Important If the rocking action in the next step fails to loosen the wiper arm, it may be necessary to use a standard top-post battery cable terminal puller to remove the wiper arm. 9. Rock the wiper arms back and forth to loosen and remove them from the wiper transmission shaft. 10. Remove the antenna mast. 11. Remove the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. 12. Remove the air inlet grille and reposition it up to the windshield. It is not necessary to disconnect the washer hose. 13. Remove the two 10 mm hex head bolts that attach the wiper module to the plenum sheet metal. 14. Disconnect the electrical connector. 15. Remove the wiper module and place on a suitable work surface. Page 4433 Fuel System Diagnosis - Steps 4-11 Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 1308 Electrical Symbols Part 3 Page 15365 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 12509 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 5131 Intake Air Temperature (IAT) Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Specifications Water Pump: Specifications Water Outlet Bolt 89 inch lbs. Water Pump Bolt 89 inch lbs. Page 15715 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5132 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Page 10654 1. Install the mode actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the air outlet duct to the console. 4. Install the screw to the air outlet duct. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the console. Mode Actuator Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator-auxiliary (1). 3. Remove the mode actuator-auxiliary (1) from the HVAC module-auxiliary. 4. Remove the retaining screws from the mode actuator-auxiliary. INSTALLATION PROCEDURE Page 3229 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 5673 Electrical Symbols Part 3 Page 1799 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13725 Front Passenger Door Module (FPDM) C1 Page 10710 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: ^ Ambient Air Temperature Sensor ^ Inside Air Temperature Sensor Assembly ^ Upper Left Air Temperature Sensor ^ Upper Right Air Temperature Sensor ^ Lower Left Air Temperature Sensor ^ Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated as shown in the table. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 7413 Important: The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position. 26. Slide the CV joint (2) onto the halfshaft bar (1). 27. Pull on the CV joint (2) to verify engagement. 28. Slide the large diameter of the CV joint seal (1), with the large retaining ring (2) in place, over the outside edge of the CV joint outer race (3). 29. Position the lip of the CV joint seal (1) into the groove on the CV joint outer race (3). 30. Manipulate the CV joint seal (1) to remove any excess air. 31. Secure the large retaining clamp (1) to the housing with J 35910 (or equivalent), a breaker bar (3), and a torque wrench (2). ^ Torque the large retaining clamp (1) to 176 Nm (130 ft. lbs.). 32. Check the gap dimension on the clamp ear. Page 15652 Tighten the two screws to 2.5 N.m (22 lb in). Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent, to the underside of the CHMSL applique. Remove the old adhesive from the liftgate glass. The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. DO NOT use commercial glass or surface cleaners. These may contain petroleum. The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply adhesive promoter, P/N 12378555 (in Canada, use P/N 88901239), to the liftgate glass surface, completely wetting the applique application area. Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the liftgate glass. Do not wipe the glass dry. Allow the liftgate glass to air dry completely. The applique must be installed within 30 minutes following the use of the promoter. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. Attach the CHMSL wire to the connector and install the grommet. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. Remove the protective liner from the tape on the applique. Attach the locating hooks on the applique to the hinge pins. Apply the applique to the liftgate glass. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure insuring complete contact of the adhesive strip to the glass. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. Clean the liftgate glass and applique area. Page 10540 ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Page 13590 14. If the vehicle is equipped with a sunroof, seat the 6 interlocking strips. 15. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 16. Install the center pillar headliner harness electrical connector to the bussed electrical center, and the block base to the floor panel. 17. Install the headliner harness retaining clips (2) to the rocker panel and the floor panel. 18. Install the headliner harness to the left center pillar. 19. Install the following headliner harness clips to the center pillar: * The center pillar harness clips (1) * The center pillar harness clips (3) * The center pillar harness clips (4) Notice: Refer to Fastener Notice in Service Precautions. 20. Install the ground terminals and the ground bolt (2) to the center pillar. Tighten the bolt to 10 N.m (88 lb in). 21. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right center pillar. 2. Install the navigation antenna cable to the right side door sill attachments. 3. Install the navigation antenna cable to the communication interface module. 22. Install the sunshades to the headliner. 23. If equipped, install the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement - Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14391 5. Install the seat cover the remainder of the way. 6. Engage the seat cover to the hook and loop retaining strips on the seat back pad. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the screw that retains the rear seat back release latch bezel to the rear seat back. Tighten Tighten the rear seat back release latch bezel screw to 3 N.m (26 lb in). Page 9184 started. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2369 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. Page 8916 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 11425 21. Remove the four push-in fasteners that attach the seat back panel to the seat back frame. 22. Remove the seat belt from the upper retractor bracket by sliding it through the slot. 23. Remove the bolt (1) attaching the upper seat belt bracket to the seat frame. 24. Remove the push-in fastener (2) from the retractor. 25. Remove the lower retractor bolt from the retractor. Page 10703 Locations View - HVAC Systems - Automatic Page 14781 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4995 Conversion - English/Metric Page 15287 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 14746 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 7821 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 6659 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 5234 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13028 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Trailblazer, Envoy, Bravada Navigation Module: Service and Repair Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the right rear seat cushion. 2. Remove the communication interface module. 3. Using a flat bladed tool, release the retaining tab on the upper bracket. 4. Slide the upper bracket inboard until the retaining tabs are released from the processor bracket. 5. Remove the upper bracket from the processor bracket. 6. Remove the nut that retains the processor bracket to the rear seat back stud. 7. Remove the processor bracket from the vehicle. INSTALLATION PROCEDURE Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 13239 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12449 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 5947 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Diagrams Engine Oil Level And Temperature Sensor Page 9224 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5488 Fuel Injector 3 Fuel Injector 4 Fuse Block - Rear Locations View Page 2987 Notice: Refer to Fastener Notice in Service Precautions. 7. Install the camshaft caps onto their original journal. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 10. Install the camshaft cover. Page 6946 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement (Body Vin Code 3) Removal Procedure Important: The front and rear sections of the cooler lines can be serviced separately. Refer to the appropriate steps when servicing individual lines. Perform the following procedure when removing the cooler lines from the quick connect fittings. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Place a drain pan under the vehicle. Page 12106 1. Position the VCIM bracket to the seat bracket. 2. Slide the VCIM bracket forward until the retaining tabs become locked to the seat bracket. 3. Ensure the retaining tab (1) on the VCIM bracket is properly seated. 4. Install the communication interface module. 5. Position the right second row seat to a passenger position. Page 12692 Conversion - English/Metric Page 9458 Multiple Junction Connector: Diagrams C200 - C203 C201 C201 Part 1 Page 256 HVAC Systems - Manual Blower Motor Control Processor - Auxiliary (Body Type VIN 6) Engine Controls - Underhood Ticking Noise Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 11273 5. Remove all loose objects from the front seats. 6. Disconnect the inflatable restraint steering wheel module coil connector, located behind the glove compartment. IMPORTANT: If the vehicle is equipped with dual stage air bags, the steering wheel module and the IP module will each have 4 wires. Refer to SIR Connector End Views for determining the high and low circuits. 7. Cut the yellow harness connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector. B. Strip 13 mm (0.5 in) of insulation from all 4 SIR wires connector leads. 9. Cut two 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the steering wheel module deployment harness. 10. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 11. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 144 Page 14630 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 14009 Disclaimer Page 5919 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Remove the bolts (2) holding the resonator to the engine. 2. Loosen the clamp (3) on the resonator. 3. Remove the resonator. 4. Disconnect the ignition coil connectors (1) from the ignition coils. 5. Remove the retaining bolts (2) from the ignition coils. Page 6900 Disclaimer Page 14443 4. Install the rear seat cushion assembly to the vehicle. Page 8629 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 13467 Disclaimer Page 15115 Electrical Symbols Part 6 Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 2705 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the spare tire carrier. 3. Remove spare wheel hoist assembly mounting bolts from the frame. 4. Remove the spare wheel hoist assembly from the vehicle. Installation Procedure 1. Install the spare wheel hoist assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install spare wheel hoist assembly mounting bolts to the frame Tighten the spare wheel hoist assembly mounting bolts to the frame to 50 Nm (37 inch lbs.). 3. Install the spare tire to the spare tire carrier. 4. Lower the vehicle. Page 4793 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1797 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 5013 Accelerator Pedal Position (APP) Sensor Page 7669 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 12650 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Page 13327 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 5793 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2351 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test ^ Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: ^ When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. ^ When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. ^ When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. ^ When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Disable the Park Brake Automatic Adjuster. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 5. Remove the rear park brake cable from the park brake actuator lever. 6. Remove the rear brake caliper and mounting bracket assembly. Page 11652 DISCLAIMER Page 4588 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 4810 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady malfunction indicator lamp (MIL) with the ignition ON and the engine OFF. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with the ignition ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Page 5953 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14166 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement Removal Procedure 1. Remove the sunroof glass panel. 2. Carefully remove the seal from the perimeter of the glass panel. Installation Procedure 1. Carefully install the seal to the perimeter of the glass panel, ensuring that the seal is fully seated. 2. Install the glass panel to the sunroof. 3. Ensure that the sunroof does not have any air or water leaks. Page 2440 6. Install the compressor suction hose to the stud on the engine. 7. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install the compressor suction hose to the engine lift bracket. 9. Install the bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). 10. Connect the compressor suction hose (1) to the accumulator. 11. Install the compressor suction hose nut to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 12. Install the sealing washers. 13. Connect the compressor suction/discharge hose to the compressor (4). 14. Install the compressor suction/discharge hose washers. 15. Install the retaining nut (3). Tighten Tighten the nut to 33 N.m (24 lb ft). 16. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 17. Leak test the fittings of the components using the J 39400. Interior - Console Power Outlet Cover/Seat Interference Console: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 8569 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 15275 For vehicles repaired under warranty, use the table. Disclaimer Page 15700 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the liftgate. 2. Lower the rear portion of the headliner by releasing the 2 headliner retaining pins. 3. Disconnect the high mount stoplamp electrical connector (2). 4. Remove the grommet (1) from the body NOTE: Do NOT raise the liftgate while the liftgate glass is open. This can result in damage to the high-mounted stoplamp, the liftgate hinges, or the liftgate glass. 5. Close the liftgate. 6. Open the liftgate window. 7. Remove the 2 screws that retain the high mount stoplamp to the lift gate window reveal molding. 8. Remove the high mount stoplamp from the vehicle. INSTALLATION PROCEDURE Air Temperature Sensor Replacement - Upper Right Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Right REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. Page 4283 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 15468 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 1475 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 4735 control module damage may occur. - If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. AFTER PROGRAMMING A CONTROL MODULE The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: Fuel trim correction - Idle Air Control (IAC) learned position - Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: The crankshaft variation learn procedure - The engine oil life reset procedure - The idle learn procedure - The inspection/maintenance complete system set procedure - The vehicle theft deterrent password learn procedure - The Throttle Position (TP) sensor learn procedure Page 3910 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8976 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Page 8447 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 23458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 11973 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 1396 Electrical Symbols Part 3 Page 3961 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM/BCM Replacement - DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Specifications Ring Gear: Specifications Front Drive Axle Ring Gear Bolts ................................................................................................................................... ................................................. 83 Nm (61 ft. lbs.) Rear Drive Axle Ring Gear Bolts ................................................................................................................................... ............................................... 120 Nm (89 ft. lbs.) Page 4304 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 4554 Electrical Symbols Part 1 Page 8067 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11635 Disclaimer Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 15850 Locations View Page 1482 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Locations Locations View Page 10406 1. Install the shock absorber to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shock absorber lower mounting bolt. Tighten the shock absorber lower mounting bolt to 80 Nm (59 ft. lbs.). 3. Install the shock absorber upper mounting bolt. Tighten the shock absorber upper mounting bolt to 80 Nm (59 ft. lbs.). Important: Before removing the support from the rear axle, ensure that the air suspension leveling sensor link is in the correct position. If the air suspension leveling sensor link is out of position, air suspension system failure will occur. 4. Remove the support from the rear axle. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Page 4579 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 11135 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: ^ Ambient Air Temperature Sensor ^ Inside Air Temperature Sensor Assembly ^ Upper Left Air Temperature Sensor ^ Upper Right Air Temperature Sensor ^ Lower Left Air Temperature Sensor ^ Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated as shown in the table. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 2474 Coolant: Fluid Type Specifications Type Goodwrench(R) or Havoline(R) Silicate-Free DEX-COOL(R) 50/50 mixture of clean, drinkable water (preferable distilled). Page 2956 Piston: Specifications Piston Diameter - (1.4961 inch) down from top 3.6627-3.6633 inch Piston to Bore Clearance 0.0004-0.0017 inch Piston to Pin Clearance 0.00012-0.0005 inch Pin Bore 0.9056-0.9058 inch Piston Pin Diameter 0.9054-0.9055 inch Page 5126 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 6988 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 8935 Brake Rotor/Disc: Service and Repair Disc Brake Backing Plate Replacement - Rear Disc Brake Backing Plate Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the park brake cable from the rear brake caliper. 4. Remove the brake caliper and bracket assembly. 5. Remove the rear brake rotor. Page 8599 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Restraints - Seat Belt Retractor Jamming Prevention Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Retractor Jamming Prevention Bulletin No.: 03-09-40-006B Date: December 02, 2005 INFORMATION Subject: Information on Avoiding Front Seat Belt Retractor Jamming When Storing Seat Belt Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and Saab 9-7X models. Please discard Corporate Bulletin Number 03-09-40-006A (Section 09 - Restraints). This bulletin is being issued to provide information to the customers if they comment that the left or right front seat belt may appear to not release from the retractor when trying to put on the seat belt. A Description For Your Customer This condition generally does not require replacement of any parts. This condition is the result of allowing the belt to enter the retractor at a high rate of speed. If the belt is allowed to go all the way back into the retractor very quickly, it is possible that the force of the belt stopping suddenly against the seat back will vibrate the retractor. This vibration "fools" the retractor into thinking that the vehicle is changing velocity. The normal function of the retractor under this condition is to lock the belt. How to Correct or Eliminate the Condition The only way to completely eliminate the condition is not to allow the belt to retract back all the way into the retractor quickly. The fast retraction usually occurs when the customer holds the latch while unbuckling and guides the webbing into the retractor quickly until it's fully stowed. As long as the customer guides the belt at a slower rate of speed, the retractor will work consistently without locking. Also, if the customer unbuckles the belt and lets the webbing retract on its own (without guiding it), there is generally enough friction from the belt against clothing to slow down the belt so it won't lock when it fully stows. If the customer does allow the belt and latch plate to retract quickly, the retractor can easily be restored to normal operation. Simply pull on the belt to create some slack in the webbing and pay back some of the webbing into the retractor. Slack can also be created by pushing on the foam at the top of the seat back. After a maximum of 10 mm (0.39 in) of webbing is introduced into the retractor, it will unlock and function again. Please demonstrate this action to your customer. After an explanation and demonstration, most customers should be able to unlock the retractor without a problem. You may give a copy of this bulletin to your customer for further reference. Disclaimer Page 8913 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 8882 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result In serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. 5. Remove the piston seal from the caliper bore. Do not use a metal tool. Page 14456 Seat Latch: Service and Repair Seat Back Release Latch Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the seat back cover and pad. 2. Remove the release latch by pinching the lower locking tabs together. 3. Remove the release cable from the release latch. INSTALLATION PROCEDURE Page 10046 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Page 8934 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front hub and bearing assembly. 4. Remove the retaining bolts for the splash shield. 5. Remove the splash shield. Installation Procedure 1. Install the splash shield. 2. Install the splash shield retaining bolts, same as wheel hub and bearing. 3. Install the front hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Lower the vehicle. Page 9113 Page 11787 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 13842 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 179 Page 5991 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 1817 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 7770 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11241 Impact Sensor: Diagrams Electronic Frontal Sensor Electronic Frontal Sensor - Left Electronic Frontal Sensor - Right Page 9546 With the new harness stretched out on a work surface, you will find two multi-terminal breakouts midway down the harness. You will need to trim these wire breakouts from the harness by cutting the four wires below at both locations as close to the taped portion of the harness as possible. ^ The Brown wire ^ The Brown/White wire ^ The Black wire ^ The Blue wire What you will end up with is a new harness with two green connectors on one end and four terminals on the other end. 27. Position the new radio speaker wiring harness to the vehicle. The small green connectors go to the upper IP speakers. 28. With the green connectors in hand, insert the new wiring harness from under the IP up to the radio area of the IP where the radio is normally positioned. 29. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 30. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 31. Disconnect the mechanics wire from the speaker wires. Connect the speaker wires to the speaker and fasten the speaker to the IP. 32. Repeat the last three steps for the right speaker. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting. 35. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 36. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 37. Route the new harness under the carpet from the rear of the console to the 8-way connector. 38. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 39. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 40. Reposition the rear electrical center through the carpet and reposition the carpet. 41. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 42. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) TEST DESCRIPTION Fuel quality can effect vehicle performance. Gasoline and gasoline blends that are contaminated or contain excessive amounts of alcohol can effect vehicle driveability, fuel economy, fuel system components and emissions. Excessive alcohol in the fuel may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions in vehicles such as hesitation, lack of power, stalling, or no start. If excessive alcohol in the fuel is suspected, then use the following procedure to test the fuel quality. TEST PROCEDURE 1. Turn ON the J 44175 Fuel Composition Tester. If the green LED does not illuminate, refer to the fuel composition tester. 2. Verify that the fuel composition tester is operational by measuring the IAC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal. IMPORTANT: Bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample from the vehicle being tested. 4. Close the bleed valve on the fuel pressure gage. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker (2). 6. Command the fuel pump ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, clean the fuel system and replace the fuel in the vehicle. Refer to Fuel System Cleaning. IMPORTANT: DO NOT allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the J 44175 could result in misdiagnosis. Page 116 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 12242 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 14092 2. Use tape to protect the mounting surface during removal. 3. To remove the luggage carrier slats, heat the slats using J 25070. Apply heat in a circular motion for 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 4. Use a plastic, flat-bladed tool to lift or remove the slats from the vehicle. 5. Remove the luggage carrier slats from the vehicle. 6. When replacing the slats, remove all of the adhesive using a 3M(TM) Scotch Brite molding adhesive remover disk, 3M(TM) P/N 07501 or equivalent. Installation Procedure Important: Apply the slats in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Heat the mounting surface to approximately 27-41°C (80-105°F). 2. Ensure that the temperature of the slats is approximately 29-32°C (85-90°F). Important: Do NOT touch the adhesive backing. 3. Remove the backing from the adhesive on the slats. 4. Align the luggage carrier slats with the masking tape. 5. Install the luggage carrier slats to the vehicle. 6. Apply equal pressure along the slats in order to uniformly bond the item to the mounting surface. 7. Remove the masking tape from the vehicle. Luggage Carrier Rivnut Replacement Luggage Carrier Rivnut Replacement Removal Procedure 1. Remove the luggage carrier. Caution: Refer to Safety Glasses Caution in Service Precautions. Page 3202 9. Remove the generator. 10. Loosen and remove the intake manifold bolts. 11. Remove the intake manifold. Installation Procedure 1. Install a new intake manifold gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the intake manifold onto the engine and secure the manifold with the bolts. ^ Tighten the intake manifold bolts to 10 Nm (89 inch lbs.). 3. Install the generator. 4. Install the brake hose to the booster. 5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent. Page 5262 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. HVAC System - Automatic Air Door Actuator / Motor: Locations HVAC System - Automatic Locations View - HVAC Systems - Automatic Page 744 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Recall - Fuel Filter Fitting Retainer Replacement Technical Service Bulletin # 02016 Date: 020501 Recall - Fuel Filter Fitting Retainer Replacement File In Section: Product Recalls Bulletin No.: 02016 Date: May, 2002 PRODUCT SAFETY RECALL SUBJECT: 02016 - FUEL FILTER FITTING DISCONNECT MODELS: 2002 CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles. Some of these vehicles have a condition where a fuel filter fitting may become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out of the fuel filter onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. Under this condition, the vehicle could be maneuvered to a stop with manual steering efforts, and sufficient power brake assist would be maintained to bring the vehicle to a stop. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. CORRECTION Dealers are to replace the fuel filter quick connect retainers. VEHICLES INVOLVED Involved are certain 2002 Chevrolet TrailBlazers, GMC Envoys, and Oldsmobile Bravadas. Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. Not all vehicles are involved. Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Important: An initial supply of parts required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 6, 2002. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. SERVICE PROCEDURE 1. Open the hood. Page 4419 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8475 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 13338 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Page 1942 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 2430 1. Apply coolant to the end of the heater inlet hose. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 3821 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2912 2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1), which is part of EN 45680-400, over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117). Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401(1). Note: Refer to Fastener Notice in Cautions and Notices. 4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten Tighten the 4 attachment bolts to 15 N.m (11 lb ft). 5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100). Page 5371 Canister Vent Valve: Description and Operation EVAP Vent Valve The EVAP vent valve (1) controls fresh airflow into the EVAP canister. The EVAP vent valve is a normally open valve. The PCM will command the valve closed during some EVAP tests, allowing the system to be tested for leaks. Page 4812 Malfunction Indicator Lamp (MIL) Inoperative - Steps 8-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Page 15463 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9143 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 12876 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 10384 1. Install the rear coil springs. 2. Raise the rear axle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shock absorber lower mounting bolts. Tighten the shock absorber lower mounting bolts to 80 Nm (59 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 790 Electrical Symbols Part 4 Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1207 Ambient Temperature Sensor / Switch HVAC: Locations Locations View - HVAC Systems - Automatic Page 5087 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 1287 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 598 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... ................................................ 140 Nm (103 ft. lbs.) Page 9374 Fuse Block - Underhood C5 Fuse Block - Underhood C7 Page 3043 14. Remove the left engine mount bracket bolts. 15. Remove the left engine mount bracket. 16. Remove the left frame engine mount bracket bolts, if required. 17. Remove the left frame engine mount bracket, if required. Installation Procedure 1. Install the left frame engine mount bracket, if removed. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the left frame engine mount bracket bolts, if removed. ^ Tighten the mount bracket bolts to 110 Nm (81 ft. lbs.). Page 10190 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 9364 Fuse Block - Rear C1 Part 2 Page 9218 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Service and Repair Trunk / Liftgate Stop: Service and Repair Bumper Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Remove the bolts that retain the bumper assembly to the body. 3. Remove the bumper assembly from the body. Installation Procedure 1. Position the bumper assembly to the body. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the bumper assembly to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Close the liftgate. Page 3684 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Locations Locations View - HVAC Systems - Automatic OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 1803 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5155 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 11509 Impact Sensor: Description and Operation Inflatable Restraint Sensing and Diagnostic Module INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Rear Axle ............................................................................................................................................. .................................................. 1.9 Liters (4.0 Pints) Rear Axle w/8.6" ring gear .............................. .................................................................................................................................... 2.28 Liters (4.8 Pints) Front Differential Front Axle ............................................................................................................................................ ................................................. 0.8 Liters (1.7 Pints) Page 12377 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 8624 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 5047 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2063 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5628 Disclaimer Page 14015 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Page 11400 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - No. 2 Rear REMOVAL PROCEDURE 1. Remove the seat assembly from the vehicle. 2. Remove the grommet (1). Discard the old grommet. 3. Remove the seat belt buckle assembly from the seat. INSTALLATION PROCEDURE Page 14745 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Radiator Cooling Fan Motor: Customer Interest Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Bulletin No.: 05-06-02-012B Date: October 19, 2006 TECHNICAL Subject: Service Engine Soon (SES) or Check Engine Light On, DTC P0480/P0526/P1481/P1484 Set (Replace Engine Cooling Fan Wiring Harness) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2005-2006 GMC Envoy Denali, Envoy XL Denali 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add DTC P1484. Please discard Corporate Bulletin Number 05-06-02-012A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the Service Engine Soon (SES) or Check Engine light is illuminated. This condition may be intermittent and upon investigation, the technician may find either DTC P0480, P0526, P1481 or P1484 set. Cause This condition may be caused by the cooling fan harness chaffing against the plastic guide it routes through. This contact may damage the insulation of the wires enclosed in that harness. Correction Replace the engine cooling fan harness using the procedure listed below. Remove the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Place the cooling fan assembly on a bench. Disconnect the harness electrical connector from the cooling fan clutch. Remove the harness from the plastic guide while feeding the wires out of the slot. Before installing the new harness, wrap the affected area on the wires with electrical tape to keep the protective sleeve in place. Be sure to keep the tape Page 15664 Electrical Symbols Part 2 Front Suspension Strut / Shock Absorber: Service and Repair Front Shock Module Replacement This article has been updated by TSB# 06-03-08-011 dated August 28,2006. Shock Module Replacement Tools Required ^ J 36607 Ball Joint Separator Removal Procedure 1. Remove the shock module upper retaining nuts. 2. Raise and support the vehicle. Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 3. Remove the tire and wheel. 4. Loosen the shock module yoke to lower control arm retaining nut. 5. Remove the shock module yoke from the lower control arm using J 36607. Page 11576 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Page 6844 For vehicles repaired under warranty, use the table. Disclaimer Page 13706 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Handle/Striker Replacement - Lift Gate Window Trunk / Liftgate Striker: Service and Repair Handle/Striker Replacement - Lift Gate Window REMOVAL PROCEDURE 1. Open the lift gate window. 2. Remove the nuts retaining the striker assembly to the lift gate window. 3. Remove the handle and striker assembly from the lift gate window. INSTALLATION PROCEDURE 1. Install the handle and striker assembly to the lift gate window. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the striker assembly to the lift gate window. Tighten Tighten the nuts to 6 N.m (53 in lb). 3. Check the lift gate window for proper operation, adjust if necessary. Refer to Striker Adjustment Lift Gate Window. Page 8157 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 12903 10. Torque all four bolts to 25 N.m (18 ft.lb). 11. Clean and prepare all bare-metal surfaces. 12. Apply a full-bodied caulk around the service hinge. 13. Refinish as necessary. 14. Install and align all of the related panels and components. GM Oil Life System (TM) - Resetting Maintenance Reminder Control Module: Technical Service Bulletins GM Oil Life System (TM) Resetting File In Section: 00 - General Information Bulletin No.: 02-00-90-001 Date: March, 2002 INFORMATION Subject: GM Oil Life System(TM) - Resetting Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada These vehicles have an oil life monitor. The GM Oil Life System(TM) will show when to change the engine oil and oil filter. The GM Oil Life System(TM) must be reset after changing the engine oil and oil filter. Resetting Procedure The current Owner's Manual contains the following reset procedure: 1. Turn the ignition to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. However, it has been found that after completing the reset procedure, the CHANGE ENG OIL light does not flash as stated in the vehicle Owner's Manual. If the CHANGE ENG OIL light goes out after the reset procedure and does not return after the next ignition cycle, then the system has been reset. If the vehicle is equipped with a Driver Information Center (DIC), then reset confirmation can also be done by verifying that the Engine Oil Life percentage value has reset to 100%. Use the above information to prevent the inadvertent replacement of the instrument cluster if there are comments that the oil life reset feature does not work. Disclaimer Page 5341 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 5107 Various symbols are used in order to describe different service operations. Air Outlet Replacement - Instrument Panel Air Register: Service and Repair Air Outlet Replacement - Instrument Panel REMOVAL PROCEDURE 1. Using a flat-bladed tool, release the left housing retaining pin and gently push the left side of the air outlet into the housing assembly. 2. With the air outlet in the housing assembly, rotate the air outlet face down. 3. Using a flat bladed tool, remove the left side of the air outlet from the housing assembly. Page 110 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 277 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 8373 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF SEAL/MOLDING REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof glass panel. 2. Carefully remove the seal from the perimeter of the glass panel. INSTALLATION PROCEDURE 1. Carefully install the seal to the perimeter of the glass panel, ensuring that the seal is fully seated. 2. Install the glass panel to the sunroof. 3. Ensure that the sunroof does not have any air or water leaks. Page 6221 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 15154 DISCLAIMER Page 12984 Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside (TrailBlazer, Envoy, Bravada) Door Handle Replacement - Rear Outside (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip that retains the lock rod to the handle. 4. Remove the lock rod from the handle. 5. Remove the nut that retains the handle and bracket to the door. 6. Remove the bracket from the handle. 7. Remove the handle from the door. Installation Procedure 1. Install the handle to the door. 2. Install the bracket to the handle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut that retains the handle to the bracket. Tighten the nut to 10 N.m (88 lb in). 4. Install the lock rod to the handle. 5. Install the clip that retains the lock rod to the handle. 6. Install the water deflector. 7. Install the door trim panel. Page 13712 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 6031 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 9708 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6430 Page 1433 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 12939 For 2007 vehicles repaired under warranty, use the table. Disclaimer Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. Page 9635 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 12840 3. Install the trailer/towing receptacle assembly to the bracket and rotate clock-wise until fully seated. 4. Connect the trailer/towing receptacle electrical connector. 5. Install the rear fascia. 6. Install the spare tire carrier. Page 13772 Disclaimer Page 5979 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 6026 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9776 C307 Part 2 Page 11836 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 1708 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 7037 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 14863 Compass: Service and Repair COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an area that is magnetically clean or free of large metallic objects. Verify there are no magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or On/Off (W/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. World Magnetic Variation Map 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or On/Off (W/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds, the display will return to a compass heading. The variance procedure is now complete. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 15781 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6804 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9549 27. Remove the CPA from the rear audio control connector and remove the eight wires from the designated cavities of the rear audio control in-line harness connector and replace them with the wires from the new harness as listed below. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. Also, this wiring harness has two Dark Blue and two Brown wires. It may be necessary to cut a small portion of the electrical tape wrap to determine which wires are paired. ^ Pair One - Remove wire in cavity B3 and insert the Brown/White wire. - Remove wire in cavity A8 and insert the Brown wire. ^ Pair Two - Remove wire in cavity A9 and insert the Dark Blue wire. - Remove wire in cavity A1 and insert the Black wire. ^ Pair Three - Remove wire in cavity B1 and insert the Brown wire. - Remove wire in cavity B5 and insert the Yellow wire. ^ Pair Four - Remove wire in cavity B6 and insert the Light Blue wire. - Remove wire in cavity B2 and insert the Dark Blue wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires as close to the taped portion of the original harness as possible. 28. Lift the carpet in the left rear door area, and slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 29. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 30. Route the new harness under the carpet from the rear of the console to the 8-way connector. 31. Remove the eight wires from the 8-way inline harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. ^ Remove wire in cavity A and insert the Gray wire. ^ Remove wire in cavity B and insert the Tan wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Light Green wire. ^ Remove wire in cavity E and insert the Yellow wire. ^ Remove wire in cavity F and insert the Brown wire. ^ Remove wire in cavity G and insert the Light Blue wire. ^ Remove wire in cavity H and insert the Dark Blue wire. ^ Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 6929 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 46 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 15469 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 6235 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 8111 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16028 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver Page 12971 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 733 Electrical Symbols Part 1 HVAC Systems - Manual Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Page 249 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 14404 7. Remove the seat electrical harness from the seat pan. 8. Remove the wire harness fasteners from the seat pan. 9. Disconnect the seat cushion heater electrical connector, if equipped. IMPORTANT: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the seat pad. 10. Separate the hook and loop retaining strips. 11. Remove the hog rings (1) from the bottom rear side of the cover. 12. Remove the 11 hog rings from the top side of the cover. 13. Remove the seat cushion trim cover and pad from the seat frame. 14. Remove the seat module retaining screw, if equipped. 15. Remove the seat module, if equipped. 16. Remove the seat cover from the seat cushion. 17. Remove the seat cushion from the seat pan. INSTALLATION PROCEDURE Page 13776 Trunk / Liftgate Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate trim panel. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the trim panel. Page 2216 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. A/T, Exhaust - Rattling Noise From Under the Vehicle Transmission Cooler: Customer Interest A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8319 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 11695 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 7024 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Procedures Trunk / Liftgate Lock Cylinder: Procedures The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Note: When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. Page 3226 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 7474 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Page 386 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7997 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 15670 Electrical Symbols Part 8 Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 12193 3. Install the screws that retain the personal message recorder to the overhead console. Tighten Tighten the screws to 0.8 N.m (7 lb in). 4. Connect the electrical connector to the personal message recorder (1). 5. Install the overhead console. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 369 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 5314 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 1656 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 112 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 9030 6. Adjust the park brake shoe (1). 7. Install the rear brake rotor. 8. Install the rear park brake cable to the park brake actuator lever. Page 4975 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Locations Locations View Page 11827 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 6122 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Page 9601 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 14422 1. Remove the two rear seat cushion bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the seat cushion assembly. 3. Remove the pull handle (1). 4. Remove the J-strips (2) securing the seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. INSTALLATION PROCEDURE Page 15402 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Power Quarter Window Switch Replacement Power Window Switch: Service and Repair Power Quarter Window Switch Replacement REMOVAL PROCEDURE 1. Remove the front overhead console. 2. Disconnect the electrical connector (1) from the quarter window switch. 3. Release the tabs retaining the quarter window switch to the overhead console. 4. Remove the quarter window switch from the overhead console. INSTALLATION PROCEDURE 1. Install the quarter window switch to the overhead console, ensuring the retaining tabs are fully seated. 2. Connect the electrical connector (1) to the quarter window switch. 3. Install the front overhead console. Page 9692 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4577 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 1471 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 12051 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9349 Auxiliary Power Outlet - Front Page 15178 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Page 5954 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 14147 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Rear REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT, Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. INSTALLATION PROCEDURE Page 1661 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Service and Repair Fuel Filler Hose: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel filler cap. 2. Remove the fuel fill pipe housing. 3. Remove the fuel fill pipe bracket nut (2). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. Page 15140 Equivalents - Decimal And Metric Part 1 Page 14644 Front Door Weatherstrip: Service and Repair Auxiliary REMOVAL PROCEDURE 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 4778 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Service and Repair Valve Cover: Service and Repair Camshaft Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Discharge the A/C. 3. Remove the A/C line at the oil level indicator tube bracket nut. 4. Remove the A/C line from the accumulator. 5. Remove the A/C bracket bolt from the engine lift hook. 6. Remove the engine lift bracket. 7. Disconnect the ignition control module electrical connectors. 8. Loosen and remove the ignition control module bolts. Page 14455 1. Install the 3 bolts securing the rear seat cushion latch to the seat pan. Tighten Tighten the rear seat cushion latch release bolts to 10 N.m (88 lb in). 2. Install the small loop (1) onto the rear seat cushion latch (2). 3. Install the strap through the opening in the seat pan. 4. Install the rear-seat cushion cover and the pad. 5. Install the rear seat cushion assembly to the vehicle. Page 12081 3. Install the 3 retaining screws to the garage door opener. Tighten Tighten the screws to 0.8 N.m (7 lb in). 4. Connect the electrical connector to the garage door opener (3). 5. Install the overhead console. Page 7027 Disclaimer Page 9790 C203 C301 Page 6124 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 2181 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 9879 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7947 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 1361 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver Page 1644 Electrical Symbols Part 8 Page 241 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 14623 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4739 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 1160 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 1592 Electrical Symbols Part 1 Page 15464 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1617 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 10093 Steering Gear: Service and Repair Rack and Pinion Gear Rack Bearing Preload Adj - Off Vehicle Rack and Pinion Gear Rack Bearing Preload Adjustment - Off Vehicle (Rack and Pinion) 1. Loosen the adjuster plug lock nut (1). 2. Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly. 3. Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the adjuster plug lock nut (1) to the adjuster plug. Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 68 Nm (50 ft. lbs.). Page 12331 Page 15360 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 8968 6. Remove the front brake pads from the mounting bracket. 7. Inspect the brake hardware. 8. Remove the brake pad retaining clips from the mounting bracket. 9. Remove the brake caliper mounting bracket retaining bolts. Page 1336 Equivalents - Decimal And Metric Part 1 Service and Repair Marker Lamp Bulb: Service and Repair PARK/TURN SIGNAL/SIDE MARKER LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the headlamp. 3. Rotate the bulb and socket counter-clockwise in order to remove the bulb and socket from the housing. 4. Remove the side marker bulb (4) or turn signal/park bulb (3) from the socket. INSTALLATION PROCEDURE 1. Install the side marker bulb (4) or turn signal/park bulb (3) to the socket. 2. Wipe the bulb with a clean cloth to ensure the bulb is free of any dirt or oil. 3. Install the bulb and socket to the headlamp by rotating the bulb and socket clockwise, locking the retaining tabs to the headlamp. 4. Install the headlamp. 5. Close the hood. Page 14309 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear No. 2 REMOVAL PROCEDURE 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad. 3. Remove the two bolts (1) securing the outer riser assembly to the seat back frame. 4. Remove the two bolts securing the inner riser assembly to the seat back frame. 5. Remove the seat back. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the two bolts securing the inner riser assembly to the seat back frame. Tighten Tighten the seat back mounting bolts to 25 N.m (18 lb ft). 2. Install the seat back cover and pad. 3. Install the head restraint assembly. Page 10951 Tighten Tighten the nuts to 5 N.m (44 lb in). 5. Install the foam insulators to the evaporator core-auxiliary lines (3). 6. Install the foam insulators to the thermal expansion valve-auxiliary (4). 7. Install the evaporator core-auxiliary. Page 5411 Accelerator Pedal Position (APP) Sensor Locations Locations View Page 12325 Page 8151 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Specifications Fluid Transfer Tube: Specifications Oil Level Indicator Bolt ......................................................................................................................... ................................................... 47 Nm (35 ft. lbs.) Page 11935 Locations Lock Cylinder Switch: Locations Locations View A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 7236 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 7120 8. Disengage the primary sock. Spring tension will push the end of the cable past the ball stud. Important: If the cable end is pushed rearward past the ball stud during the adjustment procedure, it must be released and allowed to come forward of the bail stud. The cable end must then be pushed back just enough to be installed to the ball stud. 9. Push the end of the cable until it is aligned with the ball stud. 10. Install the cable (4) to the ball stud (6). 11. Seat the primary lock (1). 12. Slide the secondary lock (2) over the primary lock. Page 6744 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer Ext, Envoy XL) Transfer Case Motor/Encoder Replacement (Trailblazer EXT, Envoy XL) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/Encoder is in the neutral position. 1. Raise the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the motor/encoder electrical connector. 4. Remove the motor/encoder mounting bolts. 5. Remove the motor/encoder assembly. Installation Procedure Page 7195 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Page 142 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 4659 Electronic Throttle Actuator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 8586 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 5432 Fuel: Service and Repair FUEL SYSTEM CLEANING 1. Remove the fuel sender assembly. 2. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations. 3. Flush the fuel tank with hot water. 4. Pour the water out of the fuel sender assembly opening. Rock the tank to be sure that removal of the water from the tank is complete. 5. Install the fuel sender assembly. Page 1762 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 414 Driver Door Module (DDM) C4 (W/Memory Features) Driver Door Module (DDM) C5 Page 15408 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 146 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 12570 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 11120 Control Module HVAC: Service and Repair Blower Motor Processor Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the HVAC module-auxiliary. 3. Disconnect the electrical connector from the blower motor processor (1). 4. Remove the retaining screws from the blower motor processor (1). 5. Remove the blower motor processor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the blower motor processor (1) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws to the blower motor processor (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the HVAC module-auxiliary. 4. Connect the electrical connector to the blower motor processor (1). 5. Install the right rear quarter trim panel. Page 15660 For vehicles repaired under warranty, use the table. Disclaimer Page 9571 For vehicles repaired under warranty, use the table. Disclaimer Page 5485 Various symbols are used in order to describe different service operations. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 2993 6. Install the fuel injector electrical connectors. 7. Install the engine electrical harness housing (1). 8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. ^ Tighten the A/C line bracket nut to 7 Nm (62 inch lbs.). 9. Install the engine lift bracket and secure the lift hook with the bolts. ^ Tighten the lift bracket bolts to 50 Nm (37 ft. lbs.). 10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. ^ Tighten the A/C bracket bolt to 10 Nm (89 inch lbs.). 11. Install the intake manifold. 12. Recharge the A/C system. Page 13698 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Specifications Fuel Level Specifications Page 11360 11. Remove the seat belt retractor bracket bolt (1) from the bracket and seat back frame. 12. Remove the seat belt retractor bracket from the seat back frame. INSTALLATION PROCEDURE 1. Position the seat belt retractor bracket on the seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Page 9742 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1977 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11850 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 3124 Electrical Symbols Part 3 Page 11692 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2445 19. Lower the vehicle. 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Cooling System. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Cooling System. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Obtain a new A/C or heater line for sectioning. IMPORTANT: Stagger the splices if repairing more than one line. 5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. IMPORTANT: The length of the replacement line must be the same as the line being replaced. 8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 11. Use the LOK prep sealant in order to prep the line ends. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J 41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Cooling System. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Page 7735 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 13810 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 5574 Electrical Symbols Part 8 Page 1725 Equivalents - Decimal And Metric Part 2 Arrows and Symbols A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Wheels - Plastic Wheel Nut Covers Loose/Missing Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5281 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 3049 14. Note: Graphic shows left, right is similar. Remove the right engine mount bracket bolts. 15. Remove the right engine mount bracket. 16. Note: Graphic shows left, right is similar. Remove the right frame engine mount bracket bolts, if required. 17. Remove the right frame engine mount bracket, if required. Installation Procedure 1. Note: Graphic shows left, right is similar. Install the right frame engine mount bracket, if removed. Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the screws from the heater core cover-auxiliary (3). 3. Remove the heater core cover-auxiliary (3). INSTALLATION PROCEDURE 1. Install the heater core cover-auxiliary (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the heater core cover-auxiliary. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the right rear quarter trim panel. Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 11180 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 9908 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Seat Belt Buckle Replacement - Front Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Front REMOVAL PROCEDURE 1. Remove the front seat assembly. 2. Disconnect the seat belt reminder wiring harness (3) on the driver's seat. 3. Remove the nut (1) which retains the seat belt buckle to the seat assembly. 4. Remove the seat belt buckle from the seat assembly. INSTALLATION PROCEDURE Page 2054 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 10655 1. Install the mode actuator (1) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator-auxiliary. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the mode actuator-auxiliary (1). 4. Install the right rear quarter trim panel. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC) in HVAC Systems - Automatic. Auxiliary HVAC When replacing the auxiliary HVAC control module it will be necessary to allow the auxiliary HVAC control module to perform a re-calibration process. When installing the auxiliary HVAC control module be sure to perform the following: 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the auxiliary HVAC control module. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. Wait 40 seconds for the auxiliary HVAC control module to re-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing an auxiliary HVAC actuator it will be necessary to allow the auxiliary HVAC control module to perform a re-calibration process. When installing the auxiliary HVAC actuator be sure to perform one of the following: Preferred Method (W/ Scan Tool) 1. Clear all DTCs 2. Place the ignition switch in the OFF position. 3. Install the auxiliary HVAC actuator. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. With the scan tool, initiate the HVAC Actuator Recal. feature of the RHVAC/RSA module Special Functions menu. 7. Verify that no DTCs have set as current DTCs. Alternate Method (W/O Scan Tool) 1. Clear all DTCs 2. Place the ignition switch to the OFF position. 3. Disconnect the scan tool. 4. Install the auxiliary HVAC actuator. 5. Re-connect all previously disconnected components. 6. Remove the HVAC B fuse for a minimum of 10 seconds. 7. Re-install the HVAC B fuse. 8. Place the ignition switch in the RUN position. 9. Wait 40 seconds for the auxiliary HVAC control module to re-calibrate. Page 7038 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Page 15772 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 14934 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14739 Electrical Symbols Part 8 Page 9795 C306 C307 Part 1 Page 4497 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test ^ Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: ^ When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. ^ When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. ^ When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. ^ When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 13726 Front Passenger Door Module (FPDM) C2 Page 12683 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 15893 Electrical Symbols Part 8 Page 14240 Memory Seat Module - Driver C2 Memory Seat Module - Driver C3 Page 12143 Electrical Symbols Part 1 Page 2200 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 4883 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: Customer Interest Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 6898 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 5646 1. Uncap the fuel fill hose (9). 2. Install the fuel fill pipe (7). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the fuel fill hose (9) to the fuel fill pipe (7). Tighten Tighten the fuel fill hose clamp (8) to 2.5 N.m (22 lb in). 4. Install the fuel fill pipe ground strap bolt (3). Tighten Tighten the fuel fill pipe ground strap bolt to 10 N.m (89 lb in). 5. Lower the vehicle. Page 7084 1. Install the transmission control. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission control bolts. ^ Tighten the transmission control bolts to 25 Nm (18 ft. lbs.). 3. Install the range selector cable (2) to the floor shift control. 4. Install the end of the range selector cable (1) to the transmission control ball stud. 5. Connect the shift lock control solenoid wiring harness. 6. Install the front floor console. 7. Check for proper operation of the floor shift control. 8. Adjust the range selector cable if necessary. Page 4573 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1622 Equivalents - Decimal And Metric Part 1 Page 12345 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 3122 Electrical Symbols Part 1 Locations Locations View Page 10214 Tighten the outer tie rod retaining nut to 45 Nm (33 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Adjust the front toe. A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 11730 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 3901 Electrical Symbols Part 6 Page 14396 1. Position the seat back cover and pad on the seat back frame. 2. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 3. Install the three hog rings (1) securing the cover to the pad. 4. Pull the cover down over the pad ensuring that the hook and loop fasteners (2, 3) are pressed together. 5. Pull the seat cover back through the opening between the seat cushion and the seat back. Page 10107 Electrical Symbols Part 7 Page 6735 Transfer Case Actuator: Specifications NVG126-NP4 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) NVG 226-NP8 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) Page 6038 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 3015 Disclaimer Page 14131 1. Position the sunshade to the vehicle from the top of the vehicle. 2. Install the retaining tabs on one side of the sunshade into the track slot of the sunroof. 3. Flex the center of the sunshade (2) upwards while simultaneously inserting the retaining tabs (3) into the track slot (1). 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. 5. Install the water trough to the sunroof from the top of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the screws that retain the water trough to the sunroof. Tighten Tighten the screws to 1 N.m (9 lb in). 7. Install the glass panel. Page 5785 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 7491 Universal Joint: Service and Repair Universal Joint Replacement- External Snap Ring Universal Joint Replacement- External Snap Ring ^ Tools Required J 9522-3 U-Joint Bearing Separator - J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or Page 3195 Engine Oil Pressure: Testing and Inspection Oil Pressure Testing Oil Pressure Testing ^ Tools Required J 21867 Pressure Gauge and Hose - J 42907 Oil Pressure Tester Adapter If the vehicle has low oil pressure perform the following tests. 1. Check the oil level. 2. Raise the vehicle and remove the oil filter. 3. Assemble the plunger valve in the large hole of J42907 (1) base and the hose in the small hole of J42907 (1) base. Connect the J21867 (2) to the end of the hose. 4. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve itself. 5. Install J42907 (1) on the filter mounting pad. 6. Start the engine and check the overall oil pressure and the oil pressure switch. The engine should be at operating temperature before checking the oil pressure. The oil pressure should be approximately 85 kPa (12 psi) at 1200 rpm using 5W30 engine oil. 7. If adequate oil pressure is indicated, check the oil pressure switch. 8. If a low reading is indicated, press the valve on the tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve would indicate a faulty pump. Page 13382 For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 14460 Seat Latch: Service and Repair Seat Cushion Latch Release Assembly Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). 4. Remove the 3 bolts securing the rear seat cushion latch to the seat pan. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 7004 Disclaimer Page 777 IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2(TM), select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 11725 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 1600 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 6007 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 15995 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Rearview Mirrors (Outside) - Uncommanded Movement Door Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 19 ft. lbs. Page 5179 Manifold Absolute Pressure (MAP) Sensor Page 13119 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 5761 Throttle Body: Description and Operation The throttle body for the TAC system is similar to a conventional throttle body with several exceptions. One exception being the use of a motor to control the throttle position instead of a mechanical cable. Another exception is the throttle position (TP) sensor. The TP sensor is mounted in the throttle body assembly. The TP sensor is 2 individual TP sensors within the throttle body assembly. Two separate signal, low reference, and 5-volt reference circuits are used to connect the TP sensors and the PCM. TP sensor 2 signal voltage increases as the throttle opens. TP sensor 1 signal voltage decreases as the throttle opens. Page 14593 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Exhaust - Exhaust Noise/Leak Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8786 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 1362 Door Switch: Diagrams LR Miniwedge (Door Jamb Switch) - LR Miniwedge (Door Jamb Switch) - LR Page 7879 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 7828 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 2620 Fuse Block - Rear C1 Part 2 Page 10750 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9794 C305 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 12246 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 4007 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 2845 The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: Beneath the lower control arms, inboard from the shock absorber mounts. - Beneath the center of the front crossmember. The rear end lift points for the floor jack are at the following locations: Beneath the axle housing, inboard from the shock absorber mounts. - Beneath the axle differential. Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: Chock the wheels at the end of the vehicle opposite the end being lifted. - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame. - Beneath the front suspension crossmember. - Beneath the axle. When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter. - The brake lines. - The brake cables. - The fuel filter. - The accelerator cables. - The transmission shift cables. Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 11940 Page 5730 Electrical Symbols Part 8 Page 4306 Conversion - English/Metric Page 12427 Page 15615 Equivalents - Decimal And Metric Part 1 Page 14631 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Electrical - Intermittent Multiple Malfunctions Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent Multiple Malfunctions File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-017 Date: August, 2002 TECHNICAL Subject: No Start, Service Engine Soon Lamp On, ABS Warning Light On, Air Bag Light On, DTCs Set, Various Door Electrical Functions Inoperative (Replace Driver and/or Passenger Door Harness and/or Repair Body Harness Connector) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT, TrailBlazer Export 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Built Prior to April, 2002 Condition Some customers may comment that the vehicle will not start and/or any of the following door electrical functions may be inoperative: ^ Power Door Locks ^ Outside Mirrors ^ Memory Seat ^ Power Windows ^ Heated Front Seats ^ Door Audio Speaker ^ Liftgate Some may comment that these conditions occur intermittently. Diagnosis of these conditions may also find that various Diagnostic Trouble Codes (DTCs) may be set. Cause Moisture intrusion through the passenger side and driver side front door-to-body harness inline connections. Correction Follow the recommended diagnostics/repair for the front door and body harness connectors listed below. Driver Door 1. Inspect the driver door harness connector (9 or 11 wires depending on vehicle option content) and terminals (inline to body harness). ^ If the connector has 11 leads, then there is no issue. Proceed to Passenger Door. ^ If the connector has 9 leads, then verify that the three empty cavities of the plastic connector are properly blocked. If all three cavities are blocked, then there is no issue. Proceed to Passenger Door. If two cavities are open, then perform the following repair procedure. - If there is no evidence of corrosion, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. - If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors subsection of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (11 wires) and terminals (inline to driver door harness). If there is evidence of corrosion, replace the mating Page 5929 Electrical Symbols Part 3 Page 14851 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 6267 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer Ext, Envoy XL) Transfer Case Motor/Encoder Replacement (Trailblazer EXT, Envoy XL) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/Encoder is in the neutral position. 1. Raise the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the motor/encoder electrical connector. 4. Remove the motor/encoder mounting bolts. 5. Remove the motor/encoder assembly. Installation Procedure Page 9055 Disclaimer Page 10944 Expansion Block/Orifice Tube: Service and Repair Expansion (Orifice) Tube Replacement Trailblazer, Envoy, and Bravada Expansion (Orifice) Tube Replacement Tools Required ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. 2. Remove the accumulator. 3. Remove the coolant reservoir. 4. Remove the evaporator tube nut (3) at the evaporator (1). 5. Remove the evaporator tube (4) from the evaporator (1). 6. Remove the O-ring seal and discard. 7. Remove the nut from the exaporator tube block fitting. 8. Separate the evaporator tubes (4,6) at the block fitting. Page 13346 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9320 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Locations Locations View Page 12494 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 6131 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 9202 Alternator: Specifications Voltage Voltage Charging Voltage 12.0 - 15.5 Volts Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) Page 3156 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 871 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 9798 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 15681 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1662 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 11609 5. Install the upper and lower trim covers. 6. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in Restraint Systems. 7. Program the Theft Deterrent Control Module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Page 5470 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 5888 Crankshaft Position (CKP) Sensor Page 12146 Electrical Symbols Part 4 Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 11248 5. Loosen the bolts (1) retaining the discriminating sensor to the frame. 6. Remove the discriminating sensor assembly from the frame (1). 7. Position the discriminating sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the discriminating sensor. 9. Remove the connector-position assurance (CPA) from the discriminating sensor electrical connector. Page 2914 8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100). 9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch (1.6 mm) of the cylinder bore sleeve above the surface of the cylinder block. 10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface. 11. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100). Cylinder Sleeve Trimming ^ EN 45680-865 Debris Collector (3) ^ EN 45680-411 Trim Tool Assembly (2) ^ Air Control Valve (1 - Part of EN 45680-411 Page 1103 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Page 1856 Electrical Symbols Part 5 Page 8207 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 9653 Fuse Block - Underhood C5 Fuse Block - Underhood C7 Page 2837 Do NOT attach the positive jumper cable to the stud located under the engine compartment fuse block cover. Doing so may blow the fuse resulting in various interior electrical system conditions. Disclaimer Page 8951 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 776 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2(TM). 33. If a control module is replaced the following service procedures must be performed: - The Crankshaft Variation Learn Procedure - The Engine Oil Life Reset Procedure - The Idle Learn Procedure - The Inspection/Maintenance Complete System Set Procedure - The Vehicle Theft Deterrent Password Learn Procedure - The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: Ensure the control module and DLC connections are OK. - Ensure the Techline(TM) operating software is up to date. - Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. - The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2(TM) to communicate with the control module. - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: The Off-Board Programming Adapter - The Tech 2(TM) - The control module - The Techline(TM) terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline(TM) terminal, select Service Programming. 3. Select Tech 2(TM), Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(TM) as described on the Techline(TM) terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2(TM), select Service Programming Request Information function. The Tech 2(TM) communicates with the control module and receives the access code. 6. With the Tech 2(TM), exit the Service Programming Request Information. 7. Disconnect the Tech 2(TM) from the Off-Board Programming Adapter. 8. Connect the Tech 2(TM) to the Techline(TM) terminal. 9. Turn ON the Tech 2(TM). 10. With the Techline(TM) terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline(TM) terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline(TM) terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline(TM) terminal automatically loads the calibration files to the Tech 2(TM). 16. After the download is complete, turn OFF the Tech 2(TM) 17. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 18. Connect the Tech 2(TM) to the Off-Board Programming Adapter. 19. With the Tech 2(TM), select Service Programming. Page 11811 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 3896 Electrical Symbols Part 1 Page 14046 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13527 Console: Service and Repair Overhead Console Replacement - Front Overhead Console Replacement - Front Removal Procedure 1. Remove the 2 screws that retain the console to the roof panel. 2. Release the front retaining tabs. 3. Lower the console and disconnect the electrical connectors as needed. 4. Remove the console from the vehicle 5. If replacing the console, remove the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. If replacing the console, remove the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 7. If replacing the console, remove the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 8. If replacing the console, remove the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 9. If replacing the console, remove the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Interior in Roof. Installation Procedure 1. If replacing the console, install the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Interior in Roof. 2. If replacing the console, install the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 3. If replacing the console, install the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 4. If replacing the console, install the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 5. If replacing the console, install the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. Position the console to the roof panel. 7. Connect the electrical connectors as needed. 8. Seat the front retaining tabs. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the 2 screws retaining the console to the roof panel. Tighten the screws to 1.2 N.m (10 lb in). Page 13212 Do not use oxyacetylene welding equipment. MIG WELD ONLY. Weld the crack/four holes that were drilled through the inner panel using the appropriate welding technique. Prior to refinishing, refer to the GM4901M-D-2006 (English) or GM4901M-D-F2006 (French) GM Approved Refinish Materials booklet for recommended products. The GM Refinish Materials information is now on the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: Go to www.gmgoodwrench.com. Click on GM Parts and Accessories link. Click on GM Technical Repair Information. Click on Paint Shop. Clean and prepare all of the welding surfaces. Return the surface to its original contour. Spot paint and clear the area around the hinges. Reinstall the liftgate. Replace the upper two bumpers and inspect the lower two bumpers. Replace as necessary. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1724 Equivalents - Decimal And Metric Part 1 Page 14457 1. Install the release cable to the release latch. 2. Install the release latch to the seat frame by pressing the latch into the seat frame until the locking tabs are fully engaged. 3. Install the seat back cover and pad. Page 4801 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 15997 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 6752 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). Locations Lock Cylinder Switch: Locations Locations View Page 10618 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5717 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5253 Electrical Symbols Part 1 Page 1274 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 4061 Electrical Symbols Part 2 Page 4970 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 8256 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Page 15138 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 10640 Mode Actuator - Auxiliary (Body Type VIN 6) Page 15476 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Description and Operation Traction Control Indicator Lamp: Description and Operation Traction Control Indicators (w/NW7) LOW TRACTION The low traction indicator is part of the traction control switch. The EBCM applies ground to the traction control active signal circuit in order to illuminate the low traction indicator during a traction control event. TRACTION OFF The traction off indicator, which is part of the traction control switch, turns OFF when ground is applied to the service traction control signal circuit. The EBCM illuminates the traction off indicator if any of the following conditions are present. ^ The EBCM inhibits the traction control system. ^ The driver manually disables the traction control system by pressing the traction control switch. ^ The automatic transmission shift lever is in the low (1) position. The EBCM inhibits the traction control system when a TCS-disabling malfunction occurs, or when the automatic engagement feature is programmed to disable the TCS when the ignition is turned ON. Refer to Programming the Traction Control Automatic Engagement Feature. Specifications Engine Mount: Specifications Engine Front Lift Bracket Bolt 37 ft. lbs. Engine Harness Bracket Bolt 37 ft. lbs. Engine Mount Bracket Bolt (engine) 37 ft. lbs. Engine Mount Bracket Bolt (frame) 81 ft. lbs. Engine Mount Nuts (upper and lower) 52 ft. lbs. Page 12969 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Page 6151 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 15767 Daytime Running Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5939 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Service Precautions Vehicle Lifting: Service Precautions Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. - Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4416 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 8833 Electrical Symbols Part 8 Page 13110 4. Attach the molding to the outside of the door with double sided tape. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip. 9. Install the inner window belt sealing strip. 10. Install the trim panel. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. INSTALLATION PROCEDURE Page 13605 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. INSTALLATION PROCEDURE 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE Page 3544 5. Using the J 46406 to secure the water pump pulley, install the fan nut to the water pump shaft in a clockwise rotation. ^ Tighten the fan hub nut to 56 Nm (41 ft. lbs.). 6. Install the transmission cooler lines to the engine and clip into the fan shroud. 7. Install the hood latch support. 8. Install the upper inlet radiator hose to the radiator. 9. Reposition the upper inlet radiator hose clamp using J 38185. 10. Fill the cooling system. Page 14853 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 15773 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8726 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 12545 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Trailblazer, Envoy, Bravada Navigation Module: Service and Repair Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the right rear seat cushion. 2. Remove the communication interface module. 3. Using a flat bladed tool, release the retaining tab on the upper bracket. 4. Slide the upper bracket inboard until the retaining tabs are released from the processor bracket. 5. Remove the upper bracket from the processor bracket. 6. Remove the nut that retains the processor bracket to the rear seat back stud. 7. Remove the processor bracket from the vehicle. INSTALLATION PROCEDURE Page 3747 1. Install the exhaust manifold heat shield with the 4 nuts. ^ Tighten the exhaust manifold heat shield nuts to 10 Nm (89 inch lbs.). 2. Install the oxygen sensor. 3. Install the oil level indicator. 4. Move the transmission filler tube back onto the stud and secure the tube with the nut. ^ Tighten the transmission filler tube bracket nut to 10 Nm (89 inch lbs.). 5. Install the air cleaner resonator outlet duct. Page 4205 Equivalents - Decimal And Metric Part 1 Page 1538 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 7712 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8836 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Body - Assist Step Skid Pad Warping Auxiliary Step / Running Board: Customer Interest Body - Assist Step Skid Pad Warping File In Section: 08 - Body and Accessories Bulletin No.: 02-08-61-002 Date: June, 2002 TECHNICAL Subject: Assist Step Skid Pad Warping (Replace Skid Pad) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Side Step Running Board (RPO BVE) Built Prior to May, 2002 Condition Some customers may comment that the assist step skid pad is warped. Cause The fasteners on the bottom side of the skid pad have interference to the attaching slots in the metal plate of the step assembly. This interference causes the pad to warp between the fasteners when exposed to sun and heat. Correction A new assist step skid pad has been released for service to correct this condition. This new pad has revised fasteners that provide more clearance to the attaching slots in the metal plate. Replace the assist step skid pads using the procedure and part numbers listed below. 1. Remove the assist step skid pad using a door trim panel tool. 2. Install the new assist step skid pad. Ensure all fasteners are fully seated. 3. Repeat the above steps for the opposite side. Parts Information Parts are currently available from GMSPO. Warranty Information Page 181 Labor Time Information Body - Rattle from Front of Vehicle Hood Latch: Customer Interest Body - Rattle from Front of Vehicle Bulletin No.: 03-08-63-003 Date: December 04, 2003 TECHNICAL Subject: Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a rattle coming from the front of their vehicle. Cause The hood latch may have been improperly adjusted. Correction Adjust the hood latch following the procedure below. 1. Open the hood and insert the prop rod. 2. Remove the grille. Refer to Grille Replacement in SI. 3. Remove the left and right adjustable rubber bumpers. 4. Return the prop rod to its secured position and close the hood in a normal manner, engaging the primary latch. 5. Loosen all three hood latch bolts. 6. Inspect the left and right side hood fit to the fender. Assure that the hood is at a minimum of 2 mm (0.078 in) below the fenders on both sides. Apply downward pressure to the center of the hood above the latch in order to gain the 2 mm (0.078 in). 7. With downward pressure to the center of the hood, tighten the latch bolts. Refer to illustration above. Tighten Tighten the latch bolts to 10 N.m (89 lb in). Page 806 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7042 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 11003 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install all of the screws to the HVAC module-auxiliary. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the mode actuator-auxiliary. 6. Install the mode actuator-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 7. Install the air temperature actuator-auxiliary. 8. Install the air temperature actuator-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 9. Install the evaporator core-auxiliary. 10. Install the blower motor-auxiliary. 11. Install the blower motor-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 12. Install the HVAC module-auxiliary. Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front REMOVAL PROCEDURE 1. Remove the seat assembly from the vehicle. 2. Remove the seat trim panel. 3. Remove the front seat back. 4. Remove the seat back cover and pad. 5. Remove the front seat back panel. 6. Remove the lumbar assembly. 7. Remove the seat belt and retractor assembly. 8. Remove 2 screws (1) securing the inflatable side impact module to the seat back frame. 9. Remove the 2 push pins (1) securing the side impact module tub to the seat back frame. Page 16084 Turn Signal/Multifunction Switch C4 Windshield Wiper Washer Switch (Multifunction Switch C3) Page 5781 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 9301 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 13713 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12448 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 5590 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 1398 Electrical Symbols Part 5 Page 2971 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 6400 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 10856 HVAC Control Module - Auxiliary (Body Type VIN 6) Part 1 Page 9782 C315 Part 2 C316 Page 4891 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) 1 Heated Oxygen Sensor (HO2S) 2 Page 6438 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 14523 Seat Adjuster Switch - Driver (W/Memory Seat) Page 7922 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 334 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 4777 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 15085 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady malfunction indicator lamp (MIL) with the ignition ON and the engine OFF. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with the ignition ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Page 209 For vehicles repaired under warranty, use the table. Disclaimer Page 1595 Electrical Symbols Part 4 Page 1309 Electrical Symbols Part 4 Page 8918 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 15024 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 2208 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 9499 C401 (Long Wheelbase, Body Type VIN 6) Page 9039 1. Install the park brake cables over the fuel tank assembly. 2. Pull the park brake cable through the frame toward the outside of the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the park brake cable retaining nuts to the underbody mounting studs. ^ Tighten the park brake cable retaining nuts to 10 Nm (7 ft. lbs.). 4. Raise the fuel tank the fuel tank to allow access to the rear park brake cable retainer above the fuel tank. 5. Install the rear support bracket for the fuel tank. 6. Remove the pole jack and the block of wood from the fuel tank. Page 12422 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 2374 Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Page 1409 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5822 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 5430 9. Pour the fuel sample from the beaker (1) into the J 44175 until the level of the fuel is at the top of each fuel test port (2). 10. Observe the diagnostic LEDs on the fuel composition tester. If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Fuel Composition Test Examples 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 10 percent ethanol, add gasoline to the fuel tank or replace the fuel in the vehicle. Page 3701 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 12501 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 6718 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 6486 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 14988 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 8032 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3029 Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Page 14970 Fuel Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 3235 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 9481 C203 C301 Page 12049 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15131 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5169 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 5475 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 647 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 13487 14. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 15. Install the right rear quarter lower trim panel. 16. Install the left rear quarter lower trim panel. 17. Install the left/right rear body side trim rear window garnish molding. 18. Install the left/right front body side window garnish molding. 19. Install the lift gate door sill plate. 20. Install the cargo tie-down loops and secure the loops with the tie-down bolts. Tighten Tighten the bolts to 35 N.m (26 lb ft). 21. Install the rear side door sill plates. 22. Install the second row seats. 23. Install the third row seats. 24. Install the luggage/cargo shade assembly, if equipped. 25. Install the cargo net, if equipped. 26. Install the front seats. Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, US P/N 12378554, US ACDELCO 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. Floor Carpet Drying Page 926 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 1972 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 11362 8. Slide the front seat back seat belt bezel onto the seat belt. 9. Install the seat belt bezel to the retractor bracket with the screw. Tighten Tighten the front seat back seat belt bezel screw to 6 N.m (53 lb in). 10. Install the seat belt anchor to the seat adjuster assembly with the nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the seat back anchor nut to 52 N.m (38 lb ft). 11. Install the seat trim panel. 12. Install the seat switch bezel. Trailblazer, Envoy, Bravada REMOVAL PROCEDURE Page 10533 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 15026 Page 3682 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4163 Conversion - English/Metric Page 442 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Specifications Tie Rod End: Specifications Outer Tie Rod Retaining Nut 33 ft. lbs. Outer Tie Rod To the Inner Tie Rod Jam Nut 55 ft. lbs. Outer Tie Rod to the Steering Knuckle Retaining Nut 33 ft. lbs. Page 5138 Electrical Symbols Part 1 Page 5484 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 4241 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 5884 Equivalents - Decimal And Metric Part 1 Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Page 1254 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 10801 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. Page 8450 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Service and Repair Coolant Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain cooling system. 2. Use a 1/4 inch drive in order to open and remove the drain cock. 3. Remove the drain cock. Installation Procedure 1. Install the drain cock. Notice: Refer to Fastener Notice in Service Precautions. 2. Using a 1/4 inch drive tighten the drain cock. ^ Tighten the drain cock to 2.0 Nm (18 inch lbs.). 3. Refill cooling system. Page 9493 C315 Part 2 C316 C500 - C599 Page 14805 Conversion - English/Metric Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 11447 3. If both the driver and passenger front safety belts lock when performing the inspection, no further action is required. If any of the seat belts did not lock up, refer to the Seat Belt Retractor Replacement Procedure, and replace the applicable retractor. Seat Belt Retractor Replacement Important The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information. Important For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Important Do not remove the seat from the vehicle when performing the following procedure. 1. Remove the SIR fuse. 2. Disconnect the side impact air bag electrical connector located under the seat. 3. If equipped, remove the lumbar knob and/or seat back recliner screw and handle. 4. Remove the screws attaching the seat switch bezel and reposition the bezel. 5. Remove the outer trim panel attaching screws and remove the panel from the side of the seat cushion. Page 8830 Electrical Symbols Part 5 Page 15940 1. Use the J 43244 in order to install the park lamp relay (1) to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. Side Impact Sensor Impact Sensor: Diagrams Side Impact Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Page 10815 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8936 6. Remove the park brake shoe. 7. Remove the rear drive axle. 8. Remove the retaining nuts from the backing plate. 9. Remove the backing plate from the rear axle housing. Installation Procedure Page 1863 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 6899 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF SEAL/MOLDING REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof glass panel. 2. Carefully remove the seal from the perimeter of the glass panel. INSTALLATION PROCEDURE 1. Carefully install the seal to the perimeter of the glass panel, ensuring that the seal is fully seated. 2. Install the glass panel to the sunroof. 3. Ensure that the sunroof does not have any air or water leaks. Page 13976 Door Module: Connector Views Driver Door Module (DDM) Driver Door Module (DDM) C1 Page 12303 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Body - Rattle from Front of Vehicle Hood Latch: All Technical Service Bulletins Body - Rattle from Front of Vehicle Bulletin No.: 03-08-63-003 Date: December 04, 2003 TECHNICAL Subject: Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a rattle coming from the front of their vehicle. Cause The hood latch may have been improperly adjusted. Correction Adjust the hood latch following the procedure below. 1. Open the hood and insert the prop rod. 2. Remove the grille. Refer to Grille Replacement in SI. 3. Remove the left and right adjustable rubber bumpers. 4. Return the prop rod to its secured position and close the hood in a normal manner, engaging the primary latch. 5. Loosen all three hood latch bolts. 6. Inspect the left and right side hood fit to the fender. Assure that the hood is at a minimum of 2 mm (0.078 in) below the fenders on both sides. Apply downward pressure to the center of the hood above the latch in order to gain the 2 mm (0.078 in). 7. With downward pressure to the center of the hood, tighten the latch bolts. Refer to illustration above. Tighten Tighten the latch bolts to 10 N.m (89 lb in). Page 14662 Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Liftgate Window Weatherstrip Replacement - Lift Gate Window Removal Procedure 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. Installation Procedure 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Page 3569 IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to 10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater corn hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Trailblazer EXT, and Envoy XL TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE Page 11887 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 11736 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 3137 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 42 Page 9310 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 10683 5. Install the lower air duct screw (4). 6. Install the right rear quarter trim panel. Page 15992 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1744 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3564 1. Install the heater core-auxiliary (2) to the HVAC module-auxiliary. 2. Install the HVAC module pass thru seal-auxiliary. 3. Install the heater core access cover-auxiliary (3) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core access cover-auxiliary (3). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the rear HVAC module-auxiliary. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement - Auxiliary Page 5056 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 4215 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 11247 Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the grille. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) or Grille Replacement (Oldsmobile) in Exterior Trim. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end discriminating sensor. Page 15801 1. If replacing the dome lamp bulb (1), install the dome lamp bulb to the socket. 2. If replacing the reading lamp bulb (1), install the reading lamp bulb to the socket. 3. Install the reflector (2) to the dome lamp, ensuring the retaining tabs are fully seated. 4. Position the lens to the headliner with the horizontal tab facing forward. Page 9431 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Diagrams Sunroof Motor Page 7945 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 14675 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. Installation Procedure 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 1340 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 12948 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 11629 Cellular Phone Microphone: Service and Repair ONSTAR MICROPHONE REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console. 2. Disconnect the microphone electrical connector to the OnStar(R) microphone (1). 3. If only the microphone removal is required, disengage the quick release tab (1) and remove the OnStar(R) microphone from the overhead console. 4. If removing the mounting bracket is required, remove the 2 retaining screws to the OnStar(R) microphone and remove the bracket from the overhead console. INSTALLATION PROCEDURE Page 12662 Electrical Symbols Part 4 Page 6508 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 6971 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Page 6741 5. Remove the motor/encoder assembly. Important: When replacing the encoder rotary position sensor follow these additional steps. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder gasket. 6. Position the motor on a work bench. 7. Release the 4 tabs that retain the motor/encoder gasket and remove the gasket (1). 8. Remove the snap ring and washer retaining the motor/encoder rotary position sensor. Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed. 9. Lift the motor/encoder rotary position sensor (2) from the motor shaft. 10. Disconnect the rotary position sensor (2) from the wiring harness. Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed. Installation Procedure Important: Provided the rotary position sensor was removed, follow steps to install the sensor, otherwise proceed to installing the motor/encoder to the transfer case. 1. Connect the wiring harness to the rotary position sensor. 2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed. Page 15401 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4264 Various symbols are used in order to describe different service operations. Page 13251 1. Install the trim panel to the liftgate. 2. Ensure that the trim panel retainers are fully seated. 3. Install the pullstrap to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screw that retains the pullstrap to the trim panel. Tighten Tighten the pullstrap screw to 4 N.m (35 lb in). 5. Close the liftgate. 6. Open the liftgate window. 7. Install the push-pin retainer. 8. Close the liftgate window. Page 11856 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 5168 Equivalents - Decimal And Metric Part 1 Page 15751 I/P Compartment Lamp Electronic Brake Control Module (EBCM) C1 Page 6006 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 3044 3. Install the left engine mount bracket and secure the bracket with the bolts (1). ^ Tighten the engine mount bracket bolts to 50 Nm (37 ft. lbs.). 4. Install the left engine mount onto the bracket. 5. Lower the engine onto the engine mounts. 6. Install the right and the left upper engine mount nuts. ^ Tighten the upper engine mount nuts to 70 Nm (52 ft. lbs.). 7. Raise the vehicle and remove the jack from under the vehicle. Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 5173 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 5694 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4696 Electrical Symbols Part 8 Page 10651 1. Remove the IP carrier. 2. Disconnect the electrical connector from the defroster actuator. 3. Remove the screws from the defroster actuator. 4. Remove the defroster actuator. INSTALLATION PROCEDURE 1. Install the defroster actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the defroster actuator screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the defroster actuator. 4. Install the IP carrier. Mode Actuator REMOVAL PROCEDURE Page 9784 C101 Part 1 Page 14090 IMPORTANT: Do NOT touch the adhesive backing. 3. Remove the backing from the adhesive on the slats. 4. Align the luggage carrier slats with the masking tape. 5. Install the luggage carrier slats to the vehicle. 6. Apply equal pressure along the slats in order to uniformly bond the item to the mounting surface. 7. Remove the masking tape from the vehicle. Luggage Carrier Rivnut Replacement REMOVAL PROCEDURE 1. Remove the luggage carrier. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. INSTALLATION PROCEDURE 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Recall 01V126000: Front Lower Control Arm Bracket Defect Control Arm: Recalls Recall 01V126000: Front Lower Control Arm Bracket Defect Vehicle Description: Sport utility vehicles. Under certain circumstances the front lower control arm brackets may fracture. This fracture could result in separation of the front lower control arm from the frame. A separation could result in loss of vehicle control, resulting in a crash. Dealers will replace the left and right front lower control arm brackets. Owner notification began by telephone on April 4, 2001. The followup letter to consumers was mailed May 3, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, Oldsmobile at 1-800-442-6537, or GMC at 1-800-462-8782. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 7838 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 5104 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4555 Electrical Symbols Part 2 Page 11957 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Locations Locations View Page 8923 Page 11361 2. Install the seat belt retractor bracket bolt (1) to the bracket and seat back frame. Tighten Tighten the seat belt retractor bracket bolt to 55 N.m (40 lb ft). 3. Position the seat belt retractor assembly onto the seat back frame. Install the push pin (2) on the seat back retractor to the seat back frame. 4. Install the lower seat belt retractor bolt. Tighten Tighten the lower seat belt retractor bolt to 55 N.m (40 lb ft). 5. Install the seat belt into the retractor bracket by guiding the seat belt through the slot in the bracket. 6. Install the seat back panel to the seat back frame. 7. Install the seat back pad and cover. Page 2071 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 2400 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Page 3024 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. Page 14379 14. Remove the seat module retaining screw, if equipped. 15. Remove the seat module, if equipped. 16. Remove the seat cover from the seat cushion. 17. Remove the seat cushion from the seat pan. INSTALLATION PROCEDURE 1. Install the seat cushion to the seat pan. 2. Install the seat cover to the seat cushion. 3. Using a side to side motion, carefully pull the seat cushion cover onto the seat pan. 4. Install the seat module, if equipped. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the seat module retaining screw. Tighten Tighten the screw to 5 N.m (44 lb in). Page 2231 Power Window Switch: Service and Repair Quarter Window Replacement Quarter Window Replacement Tools Required * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the liftgate. 2. Remove the upper quarter trim. Notice: In order to avoid damaging the antenna lead connector, follow these guidelines: * Use a plastic tool and carefully pry the connector from the window. * Do NOT pull on the connector, which may be stuck to the urethane adhesive or the headliner. Disconnect the antenna lead located on the rear quarter window, if equipped. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Keep the cutting edge of the tool against the window. Do this from inside the vehicle. 3. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 39032 or equivalent in order to remove the window. 4. If the original reveal molding on the quarter window is damaged it must be replaced. Page 5041 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4420 Equivalents - Decimal And Metric Part 1 Page 11574 Disclaimer Page 10309 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM/BCM Replacement - DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Page 2030 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11663 Disclaimer Page 230 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 15307 Speedometer Head: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 14075 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the module to the liftgate. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. LF Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 6129 Various symbols are used in order to describe different service operations. Page 13758 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 4159 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 2289 Fuel System Diagnosis - Steps 18-22 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, then an internal loss of pressure is indicated. 7. This step inspects the fuel pressure regulator for a fuel leak from the atmospheric vent. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 8. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 9. This step tests for a leaking fuel injector or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 12. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 14. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 16. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 3154 Various symbols are used in order to describe different service operations. Page 5197 Disclaimer Page 15763 Electrical Symbols Part 5 Page 13896 3. Install the battery tray brace to the vehicle. 4. Install the bolts that retain the battery tray brace to the body. Tighten the battery tray brace bolts to 10 N.m (89 lb ft). 5. Install the hood latch support. 6. Install the headlamp housing panel. 7. Install the radiator air intake baffle. Page 15328 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3595 Electrical Symbols Part 7 Page 4251 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15787 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5630 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 7606 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Page 10746 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 2666 Malfunction Indicator Lamp (MIL) Inoperative - Steps 1-7 Page 5656 Fuel Gauge Sender: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 3613 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 1713 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 8980 7. Remove the rear brake caliper from the brake caliper mounting bracket. Installation Procedure 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the rear brake caliper assembly to the mounting bracket. Page 113 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 1371 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Page 5467 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 11514 10. Disconnect the discriminating sensor (2) electrical connector. 11. Remove the discriminating sensor from the vehicle. INSTALLATION PROCEDURE 1. Position the discriminating sensor assembly above the front bumper. 2. Connect the discriminating sensor (2) electrical connector. 3. Install the connector-position assurance (CPA) to the discriminating sensor electrical connector. 4. Install the retaining bolts and protective cover (1) to the discriminating sensor. 5. Position the discriminating sensor assembly to the frame (1). NOTE: Refer to Fastener Notice in Service Precautions. Page 1943 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 12910 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill only through the hinge base (1). Do not drill through the mating surface (2). 6. Remove the hinge tab (3) before drilling, if necessary. 7. At each punch location, drill a 3-mm (1/8-in) pilot hole (1). 8. Using the pilot hole as a guide, drill through the hinge base using a 19-mm (3/4-in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 9. Remove the hinge. Page 4161 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13573 39. Connect the electrical connector to the left-hand body side window actuator. 40. Connect the electrical connector to the right-hand body side window actuator. 41. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 42. Install the right rear quarter lower trim panel. 43. Install the left rear quarter lower trim panel. 44. Install the left/right rear body side trim rear window garnish molding. 45. Install the left/right front body side window garnish molding. 46. Install the lift gate door sill plate. 47. Install the cargo tie-down loops. Tighten Tighten the cargo tie-down loop bolts to 35 N.m (26 lb ft). 48. Install the rear side door sill plates. 49. Install the second row seats. 50. Install the third row seats. 51. Install the luggage/cargo shade assembly, if equipped. 52. Install the cargo net, if equipped. Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE Page 5465 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 15460 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 14848 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 15890 Electrical Symbols Part 5 Page 7379 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 2372 Drive Belt Falls Off Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Page 13721 Door Module: Connector Views Driver Door Module (DDM) Driver Door Module (DDM) C1 Trim Panel Replacement - Knee Bolster Knee Diverter: Service and Repair Trim Panel Replacement - Knee Bolster REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the 4 trim panel retaining screws. 3. Release the clips that retain the trim panel to the IP. 4. Remove the trim panel from the IP. INSTALLATION PROCEDURE 1. Position the trim panel to the IP. 2. Seat the clips that retain the trim panel to the IP. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 4 trim panel retaining screws. Tighten Tighten the screws to 2.5 N.m (22 lb in). 4. Install the left closeout/insulator panel. Page 2882 1. Lubricate and fill the valve lash adjusters with engine oil. 2. Install the valve lash adjusters in their original locations. 3. Lubricate the valve rocker arm roller. 4. Install the valve rocker arms in their original locations. 5. Coat the camshaft journals with engine oil. 6. Install the camshafts to their original position Page 9649 Fuse Block - Underhood C2 Part 1 Page 14506 Position Sensor - Horizontal Motor (W/Memory Seat) Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 10398 6. Install the shock module yoke to lower control arm retaining nut. Tighten the shock module yoke to lower control arm retaining nut to 110 Nm (81 ft. lbs.). 7. Install the tire and wheel. 8. Lower the vehicle. Shock, Shock Component, and/or Spring Replacement Shock, Shock Component, and/or Spring Replacement Tools Required ^ J45400 Strut spring compressor Removal Procedure Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the shock module from the vehicle. 4. Remove the shock module yoke to shock absorber pinch bolt and nut. 5. Spread the shock module yoke at the pinch bolt using a flat bladed tool. 6. Remove the shock module yoke from the shock absorber. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Diagram Information and Instructions Alternator: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 2345 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 4775 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 126 (NP4) ................................................................................................................................... ............................................................. 1.8L (2.0 Qt) NVG 226 (NP8) ................................................ ................................................................................................................................................ 1.8L (2.0 Qt) Page 12682 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4075 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 13324 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Page 10621 Locations View Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 12326 Page 6392 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 14996 Fuel Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 6860 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13047 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 8346 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 13096 Rear Door Weatherstrip: Service and Repair Auxiliary REMOVAL PROCEDURE 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Specifications Crankshaft Seal Retainer: Specifications Crankshaft Rear Housing Bolt 89 inch lbs. Page 15868 Headlamp Relay: Service and Repair HEADLAMP DRIVER MODULE (HDM) RELAY REPLACEMENT TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the headlamp driver module (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the headlamp driver module (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 358 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 5831 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 10392 Install the shock module to the shock tower and lower control arm. Install the shock module yoke to the lower control arm. Lower the vehicle. Refer to Fastener Notice. Install the shock module upper retaining nuts. Tighten Tighten the shock module upper retaining nuts to 45 N.m (33 lb ft). Raise the vehicle. Install the shock module yoke to lower control arm retaining nut. Page 2648 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 5933 Electrical Symbols Part 7 Page 10625 Air Door Actuator / Motor: Locations HVAC Sytem - Manual Locations View - HVAC Systems - Manual Page 3887 Engine Control Module: Service and Repair Service Programming System (SPS) SERVICE PROGRAMMING SYSTEM (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: The Vehicle Identification Number (VIN) - The crankshaft variation learned position - The software/calibrations identification numbers - The control module security information - Flash Read Only Memory - Flash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. SERVICE PROGRAMMING METHODS The 4 methods of programming a control module and the proper tools for each method are as follows: Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle - Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. - Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle - Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle. BEFORE PROGRAMMING B CONTROL MODULE IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. - General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. - Heating, Ventilation, And Air Conditioning (HVAC) systems - Engine Cooling fans, etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. - All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Page 8798 Page 11741 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 5247 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. Page 13032 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Page 10864 1. Connect the HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 9083 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 5856 Electrical Symbols Part 3 Locations Locations View Page 5937 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4008 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Fuse Block - Rear (Short Wheelbase) Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 13352 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Blower Motor Control Processor Replacement Control Module HVAC: Service and Repair Blower Motor Control Processor Replacement REMOVAL PROCEDURE 1. Remove the right closeout panel. 2. Disconnect the electrical connector from the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor mounting screws (1). 5. Remove the blower motor control processor (2:). INSTALLATION PROCEDURE 1. Install the blower motor control processor (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor mounting screws (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector to the blower motor. 5. Install the right closeout panel. Page 8393 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 1. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 3. Install the motor/encoder electrical connector. 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 4022 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 7671 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 14843 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 5083 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 4028 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Locations Sunroof / Moonroof Module: Locations Locations View Page 2941 1. Install the coolant heater to the engine block. ^ Tighten the coolant heater to 50 Nm (37 ft. lbs.). 2. Install the coolant heater cord to the heater (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine harness bracket and secure the bracket with the bolt. ^ Tighten the engine harness bracket bolt to 45 Nm (33 ft. lbs.). 4. Secure the harnesses to the bracket. 5. Install the PCM. 6. Fill the cooling system. Page 7689 Page 8684 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 10129 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 1813 Various symbols are used in order to describe different service operations. Page 11739 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 1402 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 1215 Ambient Air Temperature Sensor Page 6423 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Page 12035 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 14146 1. Attach the mechanic's wire to the drain hose. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 2 hose clips securing the drain hose to the side door frame, right or left side, as needed. 4. Install the 2 hose clips securing the drain hose to the cowl panel, right or left side, as needed. 5. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 6. Install the headliner. Page 4482 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9293 Electrical Symbols Part 3 Page 7034 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 11420 Since there are 8 different versions of seat belts used in this field action and an extremely small number of vehicles that will require the retractor replacement (less than 50 worldwide), part numbers are not listed in this bulletin and dealer listings are not broken down by color. Dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when inspection determines that it is necessary to replace a seat belt retractor. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For PC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and PC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL Service and Repair Headlamp Bulb: Service and Repair REMOVAL PROCEDURE CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. - Leave the lamp switch OFF until the bulb change is complete. - Always wear eye protection when changing a halogen bulb. - Handle the bulb only by its base. Avoid touching the glass. - Keep dirt and moisture off the bulb. - Properly dispose of the used bulb. - Keep halogen bulbs out of the reach of children. NOTE: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Open the hood. 2. Remove the headlamp. 3. Remove the access cover from the rear of the headlamp. 4. Disconnect the electrical connector from the socket. 5. Rotate the bulb and socket counter clockwise in order to remove the bulb and socket from the housing. 6. Disconnect the electrical connector from the socket. 7. Remove the bulb and socket from the headlamp. INSTALLATION PROCEDURE IMPORTANT: Replace a high beam bulb with another high beam bulb. The high beam bulb has a black socket. - Replace a low beam bulb with another low beam bulb. The low beam bulb has a gray tip and a grey socket. Window Regulator Replacement - Rear Door (TrailBlazer EXT, Envoy XL) Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (TrailBlazer EXT, Envoy XL) Window Regulator Replacement - Rear Door (Trailblazer EXT, Envoy XL) Removal Procedure 1. Lower the window to the midway point (1), if possible. 2. Remove the rear door trim panel. 3. Remove the water deflector. 4. Loosen the regulator glass carrier bolts (2). 5. Slide the window to the full up position and tape it to the window frame. 6. Disconnect the electrical connector from the window regulator motor. 7. Disconnect the retainer (4) securing the regulator cable to the door. 8. Remove the 2 lower regulator retaining bolts (2,3). 9. Loosen the top regulator retaining bolt (1). Important: If the regulator assembly will not operate, removing the top regulator retaining bolt (1) completely will allow the regulator to be removed. 10. Remove the window regulator, lifting up and out from the keyhole slot (5) on the rear door inner panel and through the access hole. Installation Procedure 1. Install the regulator to the door through the access hole. Page 8900 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove the brake fluid with appropriate tool to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the upper brake caliper mounting bolt. 8. Rotate the rear brake caliper downward until it stops. Page 1132 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE Page 6121 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 6194 Page 5638 7. Use the following procedure with two wheel drive (2WD): NOTE: Refer to Fastener Notice in Service Precautions. 7.1. Position the fuel pipe bundle against the transmission and install the retaining bolt (3) through the bundle strap into the transmission. Tighten Tighten the fuel bundle strap retaining bolt to 3.75 N.m (33 lb in). 7.2. Install the fuel bundle into the clip at the rear of the transmission. 8. Use the following procedure with four wheel drive (4WD): 8.1. Position the fuel pipe bundle against the transmission and install the retaining bolt (3) through the bundle strap into the transmission. Tighten Tighten the fuel bundle strap retaining bolt to 3.75 N.m (33 lb in). 8.2. Install the fuel bundle into the clip at the rear of the transmission. 9. Install the fuel pipe bundle (4) into the fuel pipe clip at the rear of the engine. 10. Connect the integral clip (3) to the engine bracket. 11. Connect the EVAP purge pipe (5) to the EVAP canister purge valve. 12. Lower the vehicle. 13. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. 14. Connect the powertrain control module connectors to the powertrain control module. 15. Connect the negative battery cable. 16. Inspect for leaks using the following procedure: 16.1. Turn ON the ignition, with the engine OFF for 2 seconds. Page 1536 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14607 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 11699 Conversion - English/Metric Page 172 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Recall 01V334000: Transfer Case Control Module Update PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 13667 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 3052 14. Connect the cooling fan hub nut to the water pump shaft. 15. Install the J 41240 to the water pump pulley and tighten the cooling fan hub nut. ^ Tighten the cooling fan hub nut to 56 Nm (41 ft. lbs.). 16. Connect the battery negative cable. Page 10728 Electrical Symbols Part 4 Page 14804 Various symbols are used in order to describe different service operations. Page 11363 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the rear quarter upper trim, left or right side. 3. Remove the lower seat belt anchor bolt cover. 4. Remove the rear seat belt floor anchor bolt. 5. Remove the rear quarter lower trim, left or right side. 6. Remove the bolt that retains the rear seat belt retractor assembly to the body. 7. Remove the rear seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the rear seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the rear seat belt retractor assembly to the body. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the rear quarter lower trim, left or right side. 4. Install the rear seat belt floor anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt floor anchor bolt to 70 N.m (52 lb ft). Page 4335 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 9859 32. Reposition the rear electrical center through the carpet and reposition the carpet. 33. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 34. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 35. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in order, proceed to the next step. Otherwise, check your work. 36. Turn the key OFF. Remove the key. 37. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 38. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 39. Reinstall the rear electrical center cover. 40. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the attaching screws. 41. Reinstall the knee bolster (TrailBlazer). 42. Reinstall the left side closeout/insulator panel (TrailBlazer). 43. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 44. Reinstall the console to the vehicle and install the retainers. 45. Reinstall the shift boot and handle assembly. 46. Reinstall the console bin and retainers. 47. Reinstall the first lock pillar trim and carpet retainers to both door openings. 48. Position the driver's seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 49. Reinstall the SIR fuse # 18 in the underhood rear electrical center and close the hood. 50. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios Without Rear Audio Controls These vehicles use wiring harness P/N 15164934. 1. Remove the key from the lock cylinder. Page 10730 Electrical Symbols Part 6 Page 3589 Electrical Symbols Part 1 Page 5696 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 8953 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. Page 5404 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 6315 For vehicles repaired under warranty, use the table. Disclaimer Page 13943 Electrical Symbols Part 2 Page 4138 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5904 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) HVAC Systems - Manual Control Assembly: Diagrams HVAC Systems - Manual HVAC Control Module C1 Part 1 Page 3323 20. Remove the J 44221. 21. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown. 22. Install the top chain guide. 23. Add Threadlock GM P/N 12345496 on the top chain guide bolt threads. 24. Install the top chain guide bolts. ^ Tighten the top chain guide bolts to 10 Nm (89 ft. lbs.). 25. Install the engine front cover. 26. Install the camshaft cover. Page 4069 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8541 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 13478 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15308 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1452 Electrical Symbols Part 6 Page 2370 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Page 15967 1. Use the J 43244 in order to install the park lamp relay (1) to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. Page 13755 3. Install the actuator to the top of the latch. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 5592 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5854 Electrical Symbols Part 1 Page 15674 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 507 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Locations Locations View Page 5915 Ignition Coil: Diagrams Ignition Coil 1 Ignition Coil 2 Front Wheel Drive Shaft Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 41048 Swage Clamp Tool - J 35566 Drive Axle Seal Clamp Plier - J 8059 Snap Ring Pliers Disassembly Procedure 1. Remove the clamp from the boot with a pair of side cutters. Important: Do not damage the tripot housing (1). 2. Use a hand grinder to cut through the swage ring. 3. Remove the tripot housing (1) and the trilobal tripot bushing (2) from the halfshaft bar (5). 4. Thoroughly degrease the housing (1) and the spider assembly. 5. Discard the tripot bushing. 6. Use 320 grit 3M cloth (or equivalent) to remove any evident corrosion in the transmission sealing surface. 7. Allow the housing (1) and the spider assembly to dry. Important: Handle the tripot spider assembly (1) with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully. 8. Compress the tripot boot (4) onto the halfshaft bar (3), away from the spider assembly (1). Page 11002 Housing Assembly HVAC: Service and Repair HVAC Module Case - Auxiliary REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the screws from the blower motor-auxiliary. 3. Remove the blower motor-auxiliary. 4. Disconnect the electrical connectors. 5. Remove the evaporator core-auxiliary. 6. Remove the screws from the air temperature actuator-auxiliary. 7. Remove the air temperature actuator-auxiliary. 8. Disconnect the electrical connector. 9. Remove the screws from the mode actuator-auxiliary. 10. Remove the mode actuator-auxiliary. 11. Disconnect the electrical connector. 12. Remove all of the screws from the HVAC module-auxiliary. 13. Separate the HVAC module-auxiliary case halves (2,13). 14. Remove the mode door (15) from the HVAC module-auxiliary case half (2). 15. Remove the air temperature door (14) from the HVAC module-auxiliary case half (2). INSTALLATION PROCEDURE 1. Transfer the air temperature door (14) to the HVAC module-auxiliary case half (2). 2. Transfer the mode door (15) to the HVAC module-auxiliary case half (2). 3. Assemble the HVAC module-auxiliary case halves (2,13). Page 13878 Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. Page 3617 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Locations Locations View Page 8557 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 3524 Fan Clutch: Service and Repair Fan Clutch Replacement Removal Procedure 1. Remove the cooling fan and shroud. See: Fan Shroud/Service and Repair 2. Remove the fan clutch from the fan shroud. 3. Remove the bolts retaining the fan blade to the fan clutch. 4. Separate the fan blade from the fan clutch. Installation Procedure 1. Assemble the fan blade to the fan clutch. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the 4 bolts to the fan blade. Tighten the bolts to 27 Nm (20 lb ft). 3. Install the fan clutch to the fan shroud. 4. Install the cooling fan and shroud. See: Fan Shroud/Service and Repair Page 14966 Electrical Symbols Part 5 Page 9521 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 15491 Electrical Symbols Part 3 Page 15691 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 5085 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 1741 Electrical Symbols Part 7 Page 14072 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 5482 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8254 Page 9818 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 8846 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 10744 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4879 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 9462 Multiple Junction Connector: Diagrams C300 - C316 C301 C301 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 11669 Electrical Symbols Part 4 Page 2501 4. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the fill plug threads. 5. Install the fill plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 6. Install the fuel tank shield, if equipped. 7. Lower the vehicle. Refer to Vehicle Lifting. Page 13581 Headliner: Removal and Replacement Headliner Replacement (TrailBlazer EXT, Envoy XL) Headliner Replacement (TrailBlazer EXT, Envoy XL) Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the front and rear overhead console, If equipped. 10. Remove the video display, if equipped. 11. Remove the sunshades from the headliner. 12. Remove the sunshade retainer clips. 13. Remove the third row seats. 14. Remove the second row seats. 15. Remove the left/right front body side window garnish molding. 16. Remove the left/right rear body side window garnish molding. 17. Remove the lift gate door sill plate. 18. Remove the left rear quarter lower trim panel. 19. Remove the right rear quarter lower trim panel. 20. Remove the bolts from the cargo tie-down loops. 21. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 22. Loosen the three bolts that secure the jack carrier to the vehicle. 23. Remove the carpet from around the wheel stud. 24. Remove the body electrical block. Page 14508 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Rear Motor (W/Memory Seat) Page 8848 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15667 Electrical Symbols Part 5 Page 10145 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 3963 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 14412 6. Remove the hog rings (1) from the seat cover. 7. Carefully separate the hook and loop fastener strips (2) holding the cover to the pad. 8. Remove the hog rings (1). INSTALLATION PROCEDURE 1. Install the hog rings (1) securing the seat cover to the pad. 2. Pull the cover over the pad pressing the hook and loop fastener strips (2) together. Page 6027 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 563 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Page 13109 Rear Door Window Glass Weatherstrip: Service and Repair Window Weatherstrip Run Channel Assembly Replacement - Rear Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. Page 6555 Disclaimer Page 5454 Electrical Symbols Part 2 Page 5697 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Inflatable Restraint Side Impact Module, Left Locations View Page 15101 Oil Change Reminder Lamp: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 3127 Electrical Symbols Part 6 Page 6333 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Front Axle Actuator Page 1363 Miniwedge (Door Jamb Switch) - Liftgate Page 5323 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 4168 2. Install the heated oxygen sensor (2). Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 12775 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Assist Step Replacement Removal Procedure 1. Remove the nuts (1) that retain the assist step to the assist step support brackets. 2. Remove the assist step from the support brackets. 3. Place the assist step on a clean, prepared surface. 4. Release the fasteners (2) that retain the assist step pad to the assist step. 5. Remove the assist step pad from the assist step. Installation Procedure 1. Install the assist step pad to the assist step, ensuring that the fasteners (2) are fully seated. 2. Position the assist step to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (1) that retain the assist step to the assist step support brackets. Tighten the nuts to 25 N.m (18 lb ft). Page 15733 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 7569 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12060 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5424 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Page 13693 Electrical Symbols Part 7 Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 13947 Electrical Symbols Part 6 Page 15912 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Valve Lash Adjuster Replacement ^ Tools Required J 36660-A Torque Angle Meter - J 44222 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the exhaust and the intake sprocket bolts. 3. Install the J44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain off of the camshafts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 5. Remove the camshaft cap bolts. 6. Remove the camshaft caps. Page 7882 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 1804 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 255 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 12372 Labor Time Information Page 14930 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Body Side Hinge - A Pillar Front Door Hinge: Service and Repair Body Side Hinge - A Pillar Body Side Hinge - A Pillar REMOVAL PROCEDURE IMPORTANT: The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the four weld locations. IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during drilling. Page 13103 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. Installation Procedure 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Interior - Revised Moonroof Sunshade Replacement Technical Service Bulletin # 02-08-110-006 Date: 021001 Interior - Revised Moonroof Sunshade Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-110-006 Date: October, 2002 SERVICE MANUAL UPDATE Subject: Revised Sunshade Replacement Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada This bulletin is being issued to revise the Sunshade Replacement procedure in the Interior Trim sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Removal Procedure 1. Remove the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar. 2. Release the front assist handle from the headliner. Refer to Assist Handle Replacement. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). Front Axle - Special Policy For Service Axle Shaft: Technical Service Bulletins Front Axle - Special Policy For Service File In Section: 04 - Driveline Axle Bulletin No.: 01-04-19-001 Date: February, 2001 INFORMATION Subject: Special Service Policy for S/T Utility Front Axle Service Models: 2002 Chevrolet and GMC S/T Utility Models (Trailblazer, Envoy) 2002 Oldsmobile Bravada ADVANCE SERVICE INFORMATION Because of essential tool availability, only CERTAIN front axle service procedures will be ALLOWED. Available service procedures that require essential tools include the procedures listed below. ANY INTERNAL AXLE SERVICE THAT IS DETERMINED NECESSARY WILL REQUIRE AXLE ASSEMBLY REPLACEMENT. Service Procedures ^ Front Differential Drive Pinion Gear Seal ^ Front Differential Drive Pinion Gear Bearing Dirt Deflector ^ Front Differential Carrier Flange ^ Front Drive Axle Inner Axle Shaft Seal - Inner (Differential Carrier Assembly) ^ Front Drive Axle Inner Axle Shaft Seal - Outer (Differential Carrier Assembly) ^ Front Drive Axle Inner Axle Shaft Seal - Inner (Intermediate Shaft Bearing Assembly) ^ Front Drive Axle Inner Axle Shaft Seal - Outer (Intermediate Shaft Bearing Assembly) Special Tools Required ^ J 33782 Pinion Seal Installer ^ J 45225 Axle Seal Installer (use with tool J 8092) J 45225 was shipped in January 2001 and J 33782 was previously essential. The SMI classification has been changed for J 33782 for this new application. This special service policy will be in effect until all essential unit repair tools for the front axle are at the dealer. The unit repair service tools are anticipated to be shipped to the dealers in April, 2001. DISCLAIMER Page 4574 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14180 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad to expose the seat back frame. 3. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 4. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. INSTALLATION PROCEDURE 1. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 2. Install the seat back cover and pad on the seat back frame. 3. Install the head restraint assembly. Page 8847 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 10850 HVAC Control Module - Auxiliary (Body Type VIN 3) Page 12419 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 12591 1. Install the processor bracket to the rear seat studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the rear seat back stud. Tighten Tighten the nut to 45 N.m (33 lb ft). 3. Position the upper bracket to the processor bracket. 4. Slide the upper bracket outboard until all the retaining tabs are seated to the processor bracket. 5. Install the communication interface module. 6. Install the right rear seat cushion. Page 13800 Disclaimer Page 13365 1. Install the panel to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the panel to the liftgate, starting with the bottom center screw first. Tighten Tighten the screws to 5 N.m (44 lb in). 3. Install the bellcrank rod to the outside door release handle. 4. Install the liftgate trim panel. 5. Install the license pocket lamps. Page 8778 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 15326 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5577 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 7386 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 15540 Page 5588 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 8967 9. Install the brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Rear Brake Caliper Bracket Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanics wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the rear brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. Page 3703 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 15950 Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T79) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the fog lamp relay from the bussed electrical center. INSTALLATION PROCEDURE Page 11842 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 6002 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 960 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Electrical - Intermittent Interior Electrical Concerns Control Assembly: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 5978 Electrical Symbols Part 8 Page 4632 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 2444 Hose/Line HVAC: Service and Repair A/C Pipe Replacement/Repair - Auxiliary TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: ^ Rub-through ^ Collision damage ^ Leakage in the system Minimum Tube Length Required Table IMPORTANT: When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. IMPORTANT: The length of the replacement line must be the same as the section being replaced. 7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from the J 41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. IMPORTANT: Hold the J 41425-1 tool body with a 3/8" breaker bar. 15. Tighten the forcing screw of the J 41425-1 tool. When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to complete the line splice. 18. Verify that the LOK fittings are correctly installed. Page 4435 Fuel System Diagnosis - Steps 18-22 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, then an internal loss of pressure is indicated. 7. This step inspects the fuel pressure regulator for a fuel leak from the atmospheric vent. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 8. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 9. This step tests for a leaking fuel injector or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 12. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 14. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 16. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Page 7233 Page 12549 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 15977 Electrical Symbols Part 5 Page 5777 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 2577 Refrigerant Oil: Technical Service Bulletins A/C - Revised Compressor Oil Balancing Procedure File In Section: 01 - HVAC Bulletin No.: 02-01-38-006 Date: December, 2002 SERVICE MANUAL UPDATE Subject: Revised Compressor Oil Balancing Procedure Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada This bulletin is being issued to revise the Compressor Oil Balancing Procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Draining Procedure Important: Drain and measure as much of the refrigerant oil as possible from the removed compressor. 1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean, graduated container. Rotate the compressor shaft to assist in draining the compressor. 2. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor. 3. Properly discard the used refrigerant oil. Page 14236 Power Seat Control Module: Locations Locations View Page 14635 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Page 1632 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 15989 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 2264 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 15450 Electrical Symbols Part 3 Page 8021 4. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the fill plug threads. 5. Install the fill plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 6. Install the fuel tank shield, if equipped. 7. Lower the vehicle. Refer to Vehicle Lifting. Page 5364 Evaporative Emission (EVAP) Canister Purge Solenoid Page 13087 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 13315 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 14375 11. Remove the cover and pad from the seat back frame. INSTALLATION PROCEDURE 1. Position the pad on the seat back frame. 2. Fit the seat back cover over the top of the seat back frame and pad. 3. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 4. Install the hog rings (1) to the cover and pad. 5. Pull the seat back cover down over the pad pressing the hook and loop fastener strips (2) together. Page 5576 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 105 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 10854 HVAC Control Module C2 Page 11792 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 9313 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15645 area. Important: ^ Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the lift gate glass. ^ Do not wipe the glass dry. ^ Allow the liftgate glass to air dry completely. ^ The applique must be installed within 30 minutes following the use of the promoter. 16. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. 17. Attach the CHMSL wire to the connector and install the grommet. 18. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. 19. Remove the protective liner from the tape on the applique. 20. Attach the locating hooks on the applique to the hinge pins. 21. Apply the applique to the liftgate glass. 22. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure ensuring complete contact of the adhesive strip to the glass. 23. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). Important: The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. 24. Clean the liftgate glass and applique area. Parts Information Parts are currently available from GMSPO. Warranty Information Page 8325 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Page 4985 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 2875 Camshaft: Service and Repair Camshaft Replacement Camshaft Replacement ^ Tools Required J 44221 Camshaft Holding Tool - J 44222 Camshaft Sprocket Holding Tool - J 36660-A Torque/Angle Meter Removal Procedure 1. Remove the camshaft cover. 2. Remove the intake and the exhaust camshaft sprocket bolts. 3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain, off of the camshafts. 5. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 6. Remove the camshaft caps and store. Page 7334 18. Remove the power steering gear assembly. Refer to Power Steering Gear Replacement in Power Steering System. 19. Remove the inner shaft from the front drive axle. Refer to Inner Axle Shaft Replacement-Front Drive Axle. 20. Remove the front drive axle from the oil pan. 21. Secure the front drive axle to the frame. Page 802 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 7444 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 14808 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Amperage Generator Usage Locations Locations View Page 11941 Page 15372 Various symbols are used in order to describe different service operations. Page 5139 Electrical Symbols Part 2 Page 3606 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 7403 9. Spread the spacer rings (1) (3) using J 8059 for equivalent) to remove the spider assembly (2). 10. Remove the following items: ^ The spacer ring (1) ^ The spider assembly (2) ^ The second spacer ring (3) ^ The tripot boot (4) 11. Discard the tripot boot and spacer rings. 12. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 13. Inspect the following items: ^ The needle rollers ^ The needle bearings ^ The trunnion 14. Check the tripot housing for unusual wear, cracks, or other damage. 15. Use the appropriate kit to replace any damaged parts. Assembly Procedure Page 5156 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5693 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Disconnect the vacuum brake booster hose at the engine. 5. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine. 2. Install the vacuum brake booster check valve to the hose. 3. Install the vacuum brake booster hose clamp to the check valve. 4. Install the vacuum brake booster check valve to the vacuum brake booster. Page 9591 ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio to the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting 27. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 28. Locate the 8-way connector with the purple CPA. Separate the connector. Remove the CPA from the female side of the connector. 29. Route the new harness under the carpet from the rear of the console to the 8-way connector. 30. Remove the eight wires from the 8-way in line harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Insert the Gray wire into cavity A. ^ Insert the Tan wire into cavity B. ^ Insert the Dark Green wire into cavity C. ^ Insert the Light Green wire into cavity D. ^ Insert the Yellow wire into cavity E. ^ Insert the Brown wire into cavity F. ^ Insert the Light Blue wire into cavity G. ^ Insert the Dark Blue wire into cavity H. 31. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 32. Cut the wires and terminals from the wires you have removed from the 8-way connector as close to the taped portion of the original wiring harness as possible. 33. Reposition the rear electrical center through the carpet and reposition the carpet. 34. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 35. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 36. Insert the ignition key and turn to the RUN position Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 37. Turn the key OFF. Remove the key. Page 11279 33. Connect the deployment harness to the side impact module-left connector (1). 34. Route the deployment harness out of the driver side of the vehicle. 35. Disconnect the inflatable restraint IP module connector, located at the RH side of the instrument panel. Page 5181 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 5024 Electrical Symbols Part 3 Page 10049 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Engine Code 370 High Flow 3.1/3.5 GPM For vehicles with LL8 Pressure Relief 1500/1600 PSI Engine Code 360 High Flow 2.7/3.1 GPM For Vehicles with LL8 Pressure Relief 1500/1600 PSI Page 135 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 3146 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9495 C600 Page 4643 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 2366 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. HVAC System - Automatic Control Assembly: Service and Repair HVAC System - Automatic HVAC Control Module Replacement REMOVAL PROCEDURE 1. Remove the IP accessory trim plate. 2. Remove the HVAC control module screws. 3. Depress the HVAC control module tabs (3) and remove the HVAC control module (2) from the IP (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors (1) to the HVAC control module (2). IMPORTANT: Ensure that the HVAC control module tabs (3) lock into place. 2. Install the HVAC control module (2) into the IP (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the HVAC control module screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Page 11814 Service and Repair Antenna Mast: Service and Repair FIXED ANTENNA MAST REPLACEMENT REMOVAL PROCEDURE NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 1. Unscrew the antenna mast. 2. Remove the antenna mast from the antenna base. INSTALLATION PROCEDURE NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 6673 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 6790 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support retaining bolts. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Assembly to Case Bolt ......................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Page 13329 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Page 5500 Fuel Injector: Service and Repair REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail assembly. 2. Disconnect the fuel injector harness connector from the fuel injectors. 3. Remove the injector retainer clip (1). 4. Remove the fuel injector (3) from the fuel rail. 5. Discard the injector retainer clip (1). 6. Remove the injector O-ring seals (2, 4) from both ends of the injector. Discard the O-ring seals. INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, be sure to order the correct injector for the application being serviced. The fuel injector assembly (1) is stamped with a part number identification (2). A tour digit build date code (3) indicates the month (4), day (5), year (6), and the shift (7) that built the injector. Page 4137 Electrical Symbols Part 8 Page 1876 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3602 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 106 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 3877 Powertrain Control Module (PCM) C2 Part 1 Page 4093 Conversion - English/Metric Page 15889 Electrical Symbols Part 4 Page 12302 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 15451 Electrical Symbols Part 4 Page 1748 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 12139 Locations View Page 1470 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 6243 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 12770 For vehicles repaired under warranty, use the table. DISCLAIMER Technical Service Bulletin # 02-08-61-002 Date: 020601 Body - Assist Step Skid Pad Warping File In Section: 08 - Body and Accessories Bulletin No.: 02-08-61-002 Date: June, 2002 TECHNICAL Subject: Assist Step Skid Pad Warping (Replace Skid Pad) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Side Step Running Board (RPO BVE) Built Prior to May, 2002 Condition Some customers may comment that the assist step skid pad is warped. Cause The fasteners on the bottom side of the skid pad have interference to the attaching slots in the metal plate of the step assembly. This interference causes the pad to warp between the fasteners when exposed to sun and heat. Correction A new assist step skid pad has been released for service to correct this condition. This new pad has revised fasteners that provide more clearance to the attaching slots in the metal plate. Replace the assist step skid pads using the procedure and part numbers listed below. 1. Remove the assist step skid pad using a door trim panel tool. Front Lower Control Arm Control Arm: Specifications Lower Control Arm Bracket Front Mounting Bolt 192 ft.lbs. Lower Control Arm Bracket Front Mounting Bolt 192 ft. lbs. Lower Control Arm Bracket Rear Mounting Bolt 177 ft. lbs. Lower Control Arm to the Lower Control Arm Bracket Mounting Nuts 81 ft. lbs. Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement - Front (Chevrolet (X88) ONLY) Removal Procedure 1. Remove the grille 2. Remove the front fascia. 3. Remove the front impact bar. 4. Place the impact bar on a clean, prepared surface. 5. Remove the bolt that retains the tow hook to the impact bar. 6. Remove the tow hook from the impact bar. Installation Procedure 1. Install the tow hook to the impact bar, ensuring that the locating pin is properly indexed to the impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt which retains the tow hook to the impact bar. Tighten the bolt to 50 N.m (37 lb ft). 3. Install the impact bar. 4. Install the fascia. 5. Install the grille. Page 8861 Brake Warning Indicator: Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Page 4344 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 1896 Impact Sensor: Diagrams Electronic Frontal Sensor Electronic Frontal Sensor - Left Electronic Frontal Sensor - Right Page 14689 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. Installation Procedure 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure Page 5489 Fuel Injector 5 Fuel Injector 6 Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: Customer Interest Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 14064 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE Page 15320 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 1886 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 12553 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Inflate the tire to the manufactures specified pressure as stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5. Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 7. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 10. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the valve stem on the wheel. 13. Install the tire to the wheel. 14. Inflate the tire to the manufactures specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 16. Balance the tire and wheel. 17. Install the tire and wheel. 18. Lower the vehicle. Page 15920 License Plate Lamp: Connector Views License Lamp - Left License Lamp - Right Page 9860 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove the shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 15. Lift the console, disconnect the wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (TrailBlazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Light Blue wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Yellow wire. Page 102 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 14735 Electrical Symbols Part 4 Page 12058 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12157 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 6193 Page 7965 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 11832 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 6494 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Specifications Piston Ring: Specifications Piston Ring Top Groove to Ring Side Clearance 0 0017-0.0037 inch Second Groove to Ring Side Clearance 0.0017-0.0037 inch Oil Control Groove to Ring Side Clearance 0.0023-0.0085 inch Top Ring Gap - (3.66 inch) down from top of cylinder 0 0079-0.0157 inch Second Ring Gap - (3.66 inch) down from top of cylinder 0.0118-0.0197 inch Oil Control Ring Gap- (3.66 inch) down from top of cylinder 0.0098-0.0299 inch Page 12527 Page 9434 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 3655 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Page 12165 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 12368 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 11680 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12205 Alarm Module: Service and Repair Theft Deterrent Module Replacement THEFT DETERRENT - IMMOBILIZER THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the upper and lower trim covers. 3. Remove the lock cylinder. 4. Disconnect the connector from the theft deterrent control module. 5. If necessary, disconnect the connector from the ignition lock cylinder case (1). 6. Remove the theft deterrent control module (2) from ignition lock cylinder case assembly (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2) onto the ignition lock cylinder case assembly (1). CAUTION: Refer to SIR Inflator Module Coil Caution in Service Precautions. 2. Connect the connector to the theft deterrent control module. 3. If necessary, connect the connector to the ignition lock cylinder case. 4. Install the lock cylinder. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 5964 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 2001 Page 10998 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement - Auxiliary REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Remove the nuts (3) from rear A/C line block fittings. IMPORTANT: Cap or tape the open A/C refrigerant lines immediately. 5. Remove the A/C line block fittings and discard the O-ring seals. 6. Remove the nuts from the heater hoses block fittings. 7. Remove the heater hoses block fittings from the HVAC module-auxiliary. 8. Remove the nuts from the HVAC module studs. 9. Lower the vehicle. 10. Remove the right side rear quarter trim. Page 14980 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 7939 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4299 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Engine - Piston Application/Usage Piston: Technical Service Bulletins Engine - Piston Application/Usage Bulletin No.: 03-06-01-028 Date: November 19, 2003 INFORMATION Subject: Information on Correct Piston Usage Models: 2002-2003 Chevrolet Trailblazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Inline 6 Engine (VINS - RPO LL8) Should any of the above vehicles require a piston for any reason, the following replacement part number should be used. 88984235 - Standard size piston with piston pin and rings. Although this replacement piston may not appear to match the piston that is removed, it has been designed to replace all 2002 and 2003 model year engine pistons. This change was implemented into production engines beginning with EUN (engine unit number): V301290522. The EUN may be found on the left side of the engine under the A/C compressor bracket or at the rear on the back of the cam cover. Important: When replacing pistons, all six pistons must be replaced if the EUN is below the above number or if the EUN cannot be located. If pistons of different types were installed in the engine, excessive engine vibration would result. Piston rings for these engines will not be released and will require a piston change if a piston ring change is indicated. Parts Information Parts are expected to be available from GMSPO on December 1, 2003. Disclaimer Page 15982 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15718 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Actuator Bolt First pass 18 ft. lbs. Second pass 135° Intake Camshaft Sprocket Bolt First pass 15 ft.lbs. Second Pass 100° Page 234 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12664 Electrical Symbols Part 6 Page 13708 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 14054 Locations View Page 2268 Frame Angle Measurement (Express / Savana Only) ........ Page 11129 Locations View - HVAC Systems - Automatic Page 8978 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the front brake caliper to the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front brake caliper mounting bolts. ^ Tighten the front brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Important: DO NOT reuse the metal/copper gaskets. Use only new metal/copper gaskets. 6. Install the NEW metal/copper gaskets to the front brake caliper bolt. 7. Install the front brake hose bolt and gaskets. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Rear Brake Caliper Replacement - Rear Page 9862 38. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 39. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 40. Reinstall the rear electrical center cover. 41. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate, and install the retainers. 42. Reinstall the knee bolster (TrailBlazer). 43. Reinstall the left side closeout/insulator panel (TrailBlazer). 44. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 45. Reinstall the console to the vehicle and install the retainers. 46. Reinstall the shift boot and handle assembly. 47. Reinstall the console bin and retainers. 48. Reinstall the first lock pillar trim and carpet retainers to both door openin9s. 49. Position the drivers seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 50. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 51. Connect the Tech 2(R) and clear codes. Page 3954 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 3403 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12687 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 13460 There may be a lack of sealer under the "A" pillar reveal molding push nuts. Refer to the illustration above. Cause 4 The push-in retainers at the base of the auxiliary weatherstrip may not be seated fully. Refer to the illustration above. Cause 5 There may be a gap between the many pieces of sheet metal under the primary seal flange. If this is present, water may enter under the primary seal retainer and into the vehicle between the gaps in the sheet metal flange and end up under the carpet. Refer to the illustration above. Correction 1 Page 5557 Fuel Pressure: Testing and Inspection SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Fuel System Diagnosis - Steps 1-3 Page 14910 DISCLAIMER Page 3801 Locations View Page 171 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 9494 C500 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 3528 Engine Compartment Fan: Service and Repair Cooling Fan and Shroud Replacement ^ Tools Required J 41240 Fan Clutch Remover and Installer - J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air intake baffle. 2. Remove the hood latch support. 3. Disconnect the transmission cooler lines at the engine and release the lines from the fan shroud. 4. Remove the 2 upper bolts on the fan shroud. 5. Reposition the upper inlet radiator hose clamp using J38185. 6. Remove the upper inlet radiator hose from the radiator. 7. Remove the electrical connector from the shroud. 8. Position the water pump so the bolts are aligned in the vertical. 9. Remove the fan hub nut from the water pump shaft in a counterclockwise rotation. Using the J 41240, in order to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft. Page 4175 Electrical Symbols Part 1 Page 4625 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 3150 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 1338 Various symbols are used in order to describe different service operations. Page 15902 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 609 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 12256 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 12690 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Interior - Power Memory Seat Inoperative Power Seat Control Module: Customer Interest Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 6703 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 2155 Disclaimer Page 9433 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 3364 Disclaimer Page 5038 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 13753 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the rotor. Important: Do not hammer on a wheel stud. 4. Remove the wheel stud bolt using J43631. Installation Procedure 1. Install the wheel stud to the wheel hub and bearing. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 4 washers and the nut to the wheel stud. Tighten the wheel stud nut to 130 Nm (95 ft. lbs.), drawing in the wheel stud. 3. Remove the nut and the washers. 4. Install the rotor. 5. Install the tire and the wheel. 6. Lower the vehicle. Interior - Cargo Cover Handle is Broken Cargo Cover: All Technical Service Bulletins Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 501 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 5828 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14529 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 11000 1. Install new HVAC module pass through seal. 2. Install the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the HVAC module mounting bolts (5). Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Install the air outlet ducts (5). 5. Connect the electrical connectors. 6. Install the right side rear quarter trim panel. 7. Raise and support the vehicle. Page 10273 11. Remove lower ball joint retaining nut. 12. Disconnect lower ball joint from steering knuckle using J43631. Important: Take care not to disengage the axle shaft from the transmission (4WD Only). 13. Pivot the the lower control arm outward and downward in order to disconnect the lower control arm from the lower control arm bracket. 14. Remove the lower control arm from the steering knuckle. Installation Procedure 1. Install the lower control arm to the steering knuckle. Important: Take care not to disengage the axle shaft from the transmission. 2. Pivot the the lower control arm outward and upward in order to connect the lower control arm to the lower control arm bracket. 3. Install the lower control arm to the lower control arm bracket. Page 15373 Conversion - English/Metric Page 14857 Conversion - English/Metric Page 5042 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 11924 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 15743 Cornering Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 4881 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9982 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Page 10152 12. Disconnect the lower intermediate shaft boot from the power steering gear and remove the intermediate shaft boot from the vehicle. Important: Note the relationship of the intermediate shaft to the power steering gear and the intermediate shaft to the steering column in order to ensure proper installation. 13. Remove the lower intermediate shaft to the power steering gear input shaft pinch bolt. 14. Disconnect the lower intermediate shaft from the power steering gear. 15. Remove the lower intermediate shaft from the vehicle. 16. Replace the lower intermediate shaft, P/N 15155707. Parts Information Warranty Information Page 771 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - 1 The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. POWERTRAIN CONTROL MODULE (PCM) - 2 The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) HVAC Systems - Manual Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Rearview Mirrors (Outside) - Uncommanded Movement Door Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Memory Seat Switch Replacement REMOVAL PROCEDURE Page 8222 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 13196 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 9855 With the new harness stretched out on a work surface, you will find two multi-terminal breakouts midway down the harness. You will need to trim these wire breakouts from the harness by cutting the four wires below at both locations as close to the taped portion of the harness as possible. ^ The Brown wire ^ The Brown/White wire ^ The Black wire ^ The Blue wire What you will end up with is a new harness with two green connectors on one end and four terminals on the other end. 27. Position the new radio speaker wiring harness to the vehicle. The small green connectors go to the upper IP speakers. 28. With the green connectors in hand, insert the new wiring harness from under the IP up to the radio area of the IP where the radio is normally positioned. 29. Through the left side speaker opening, slide a piece of mechanics wire to the area of the radio. 30. Attach the green connector with the two blue wires to the mechanics wire and gently pull the wiring pigtail into the speaker opening. 31. Disconnect the mechanics wire from the speaker wires. Connect the speaker wires to the speaker and fasten the speaker to the IP. 32. Repeat the last three steps for the right speaker. 33. Position the radio to the IP opening, reconnect the connectors and install the retainers. 34. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting. 35. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 36. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 37. Route the new harness under the carpet from the rear of the console to the 8-way connector. 38. Remove the four wires from the 8-way harness connector and replace them with the wires from the new harness. DO NOT UNTWIST THE WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 39. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 40. Reposition the rear electrical center through the carpet and reposition the carpet. 41. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 42. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 827 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 4158 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 13952 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector on the intake stroke for each cylinder. ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high, or too low, will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. Fuel injector coil windings are affected by temperature. The resistance of fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS ^ Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. ^ Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. ^ Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. ^ If the fuel injector coil test does not isolate the condition, perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics TEST DESCRIPTION Page 3743 9. Loosen and remove the exhaust manifold bolts. 10. Remove the exhaust manifold. 11. Remove the exhaust manifold gasket. Installation Procedure 1. Install a new exhaust manifold gasket. 2. Install the exhaust manifold. Notice: Refer to Fastener Notice in Service Precautions. 3. With threadlock GM P/N 12345493 (Canadian P/N10953488) on the manifold bolts, install the bolts onto the manifold. 3.1. Tighten the exhaust manifold bolts first pass in sequence to 25 Nm (18 ft. lbs.). 3.2. Tighten the exhaust manifold bolts second pass in sequence to 25 Nm (18 ft. lbs.). 3.3. Tighten the exhaust manifold bolts final pass in sequence to 25 Nm (18 ft. lbs.). Page 4809 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Page 13408 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield. 3. Remove the evaporative emission (EVAP) canister from its mounting bracket. Do not disconnect the canister lines. 4. Support the transmission with a transmission jack. 5. Remove the transmission mount to the transmission support retaining nuts. 6. Remove the lower transmission support to the frame mounting bolts. 7. Remove the upper transmission support to the frame mounting bolts. 8. Remove the transmission support from the frame. Installation Procedure Page 11858 Page 10492 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Air Cleaner Outlet Resonator Replacement Resonator: Service and Repair Air Cleaner Outlet Resonator Replacement REMOVAL PROCEDURE 1. Disconnect the air cleaner outlet duct. 2. Loosen the throttle body clamp (1). 3. Disconnect the fuel pressure regulator vacuum supply from the resonator. 4. Remove the resonator to engine bolts (4) from the resonator. 5. Disconnect the crankcase ventilation hose (1) from the port (2). 6. Remove the resonator assembly from the engine. INSTALLATION PROCEDURE Page 6766 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 12814 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 02-08-62-001 Date: 020801 Body - Front Fascia is Loose File In Section: 08 - Body and Accessories Bulletin No.: 02-08-62-001 Date: August, 2002 TECHNICAL Subject: Front Fascia Loose (Replace Front Fascia Pencil Braces) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22375120 Page 11402 Seat Belt Buckle: Service and Repair Seat Belt Side Buckle Replacement - Rear Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Adjust the rear seats and seat backs to a cargo position. 2. Loosen the center seat belt anchor bolt that retains the seat belt to the seat belt buckle/anchor plate assembly. 3. Remove the left rear seat back rear mounting nut that retains the left seat back to the floor panel. 4. Remove the assembly clip that retains the seat belt buckle/anchor plate assembly to the rear seat back hinge bracket. 5. Remove the seat belt buckle and anchor plate assembly from the rear seat back hinge bracket. 6. Remove the center seat belt anchor bolt from the seat belt buckle/anchor plate assembly. 7. Remove the center seat belt anchor from the seat belt buckle/anchor plate assembly. INSTALLATION PROCEDURE IMPORTANT: ^ When installing the center seat belt anchor to the seat belt buckle/anchor plate assembly, ensure that the center seat belt webbing is not twisted. ^ Ensure that the center seat belt anchor is properly indexed between the locating tangs on the seat belt buckle/anchor plate assembly. 1. Position the center seat belt anchor to the seat belt buckle and anchor plate assembly. NOTE: Refer to Fastener Notice in Service Precautions. Page 5148 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4876 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10649 1. Remove the I/P carrier.See: Instrument Panel, Gauges and Warning Indicators 2. Remove the air temperature actuator-left (1) retaining screws. 3. Disconnect the air temperature actuator-left electrical connector. 4. Remove the air temperature actuator-left. INSTALLATION PROCEDURE 1. Install the air temperature actuator-left (1) NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air temperature actuator-left retaining screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the air temperature actuator-left electrical connector. 4. Install the I/P carrier.See: Instrument Panel, Gauges and Warning Indicators 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Right REMOVAL PROCEDURE Page 370 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 15421 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14091 Luggage Rack: Removal and Replacement Luggage Carrier Replacement Luggage Carrier Replacement Removal Procedure 1. Using a flat bladed tool, carefully remove the finish covers (3) from the luggage carrier side rails (2). 2. Unlock the cross rails (4) by releasing the locking tab (1) on the end of each cross rail. 3. Slide the cross rails forward and remove from the side rails. 4. Remove the bolts that retain the side rails to the roof panel. 5. Remove the side rails from the roof panel. Installation Procedure 1. Position the side rails (2) to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the side rails to the roof panel, starting with the rearmost bolt first on each side. Tighten the luggage carrier side rail bolts to 5 N.m (44 lb in). Important: Ensure that the loops on the cross rails are indexed toward the front of the vehicle. 3. Install the cross rails (4) to the side rails. 4. Lock the cross rails to the slide rails. 5. Install and secure the finish covers (3) to the side rails. Luggage Carrier Slats Replacement Luggage Carrier Slats Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. Mark the location of the luggage carrier slats on the roof with masking tape. Page 6686 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 6684 11. Using J2845fl release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 12951 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 7585 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 9971 12. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 13. Adjust the front toe. Page 12744 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 4208 Conversion - English/Metric Page 15120 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5593 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1902 Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the grille. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) or Grille Replacement (Oldsmobile) in Exterior Trim. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end discriminating sensor. Page 15852 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the flasher retaining bracket from the insulator panel. 3. Disconnect the flasher from the electrical connector. 4. Remove the flasher from the vehicle. INSTALLATION PROCEDURE 1. Position the flasher to the insulator panel. 2. Connect the electrical connector to the flasher. 3. Install the flasher retaining bracket to the insulator panel. 4. Install the left closeout/insulator panel. Page 7540 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 8538 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 4489 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 5862 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Engine Controls - SES Lamp ON/DTC P0135 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 10806 1. Install the condenser to the radiator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws to the condenser. Tighten Tighten the screws to 5 N.m (44 lb in). 3. Install the radiator. 4. Connect the evaporator tube (4) to the condenser (3). 5. Install the retaining nut to the evaporator tube (4) at the condenser (3). Tighten Tighten the nut to 28 N.m (21 lb ft). 6. Connect the compressor discharge hose (2) to the condenser (4). 7. Install the retaining nut (1) to the compressor discharge hose (2) at the condenser (4). Tighten Tighten the nut to 28 N.m (21 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Install the upper radiator battle 10. Leak test the fittings of the components using the J 39400-A. Page 5770 Electrical Symbols Part 4 Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 7668 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 12895 5. Center punch each weld location. IMPORTANT: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. At each punch location, drill a 3 mm (1/8 in.) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in.) rotabroach hole saw or equivalent (2). IMPORTANT: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 3133 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 3744 4. Install the exhaust manifold heat shield studs, if required. ^ Tighten the heat shield studs to 10 Nm (89 inch lbs.). 5. Install the oxygen sensor. 6. Install the exhaust manifold heat shield. 7. Add anti-seize compound GM P/N 12371386 to the exhaust manifold heat shield nuts. 8. Install the exhaust manifold heat shield nuts. ^ Tighten the exhaust manifold heat shield nuts to 5 Nm (44 inch lbs.). 9. Raise the vehicle. 10. Install the exhaust pipe to the manifold with seal and secure the pipe with the nuts. ^ Tighten the exhaust pipe nuts to 50 Nm (37 ft. lbs.). 11. Lower the vehicle. Page 15673 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 10716 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement REMOVAL PROCEDURE 1. Remove the grille. 2. Remove the ambient air temperature sensor (1) to the headlamp assembly. 3. Remove the ambient temperature sensor from the panel assembly. 4. Disconnect the electrical connector from the ambient air temperature sensor. INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (1) to the headlamp assembly. 2. Connect the electrical connector to the ambient temperature sensor. 3. Install the ambient temperature sensor retaining clip to the headlamp panel assembly. 4. Install the grille. Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6099 Electrical Symbols Part 3 A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 10257 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 4622 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9417 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 5309 Electrical Symbols Part 8 Page 8929 Brake Rotor Replacement- Rear Removal Procedure ^ Tools Required J 42450-A Wheel Hub Resurfacing Kit - J 21177-A Drum to Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, using a appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 14965 Electrical Symbols Part 4 Page 9203 Locations View Page 16017 Stop Lamp Switch Garnish Molding Replacement - Body Side Window Front (TrailBlazer EXT, Envoy XL) Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Front (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Page 11720 Page 3699 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 2213 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 12602 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4176 Electrical Symbols Part 2 Page 8559 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12663 Electrical Symbols Part 5 Engine Controls - MIL ON/Delayed Downshift/Fan Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Delayed Downshift/Fan Noise File In Section: 06 - Engine/propulsion System Bulletin No.: 01-06-04-052B Date: May, 2004 OBD SOFTWARE UPGRADE Subject: On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the powertrain control module (PCM) on all affected vehicles, as identified above, including vehicles in new dealer inventory, used inventory, and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table. *This a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide. Page 4181 Electrical Symbols Part 7 Locations Locations View Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Door Window Regulator Replacement (Power) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Power) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Disconnect the electrical connector from the regulator motor. 6. Loosen the upper 2 bolts that retain the regulator assembly to the door. 7. Remove the remaining 3 bolts that retain the window regulator assembly and the motor to the door. 8. Lift the regulator assembly upward in order to release the upper 2 bolts. 9. Rotate the upper portion of the regulator assembly forward. 10. Beginning with the lower portion, remove the regulator assembly through the door opening. 11. Place the regulator assembly on a prepared surface. 12. Remove the upper 2 bolts from the regulator assembly. INSTALLATION PROCEDURE 1. Partially install the upper 2 bolts to the regulator assembly. 2. Beginning with the upper portion, install the regulator assembly through the door opening in a semi-horizontal position. 3. Position the regulator assembly fully forward into the door cavity. 4. Rotate the regulator assembly to a vertical position. 5. Lower and hang the regulator assembly onto the door sheet metal using the upper 2 bolts that were previously installed. NOTE: Refer to Fastener Notice in Service Precautions. Page 15759 Electrical Symbols Part 1 Page 174 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 13687 Electrical Symbols Part 1 Page 6969 Disclaimer Page 8772 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 9772 C304 Part 1 Page 4045 Fuel Tank Pressure (FTP) Sensor Specifications Sensor Resistance Table - HVAC Systems - Automatic Page 14976 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 7971 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 14571 Disclaimer Page 5989 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Transfer Case Shift Control Module C1 Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 6.6L (7.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Electrical - Intermittent Multiple Malfunctions Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent Multiple Malfunctions File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-017 Date: August, 2002 TECHNICAL Subject: No Start, Service Engine Soon Lamp On, ABS Warning Light On, Air Bag Light On, DTCs Set, Various Door Electrical Functions Inoperative (Replace Driver and/or Passenger Door Harness and/or Repair Body Harness Connector) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT, TrailBlazer Export 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Built Prior to April, 2002 Condition Some customers may comment that the vehicle will not start and/or any of the following door electrical functions may be inoperative: ^ Power Door Locks ^ Outside Mirrors ^ Memory Seat ^ Power Windows ^ Heated Front Seats ^ Door Audio Speaker ^ Liftgate Some may comment that these conditions occur intermittently. Diagnosis of these conditions may also find that various Diagnostic Trouble Codes (DTCs) may be set. Cause Moisture intrusion through the passenger side and driver side front door-to-body harness inline connections. Correction Follow the recommended diagnostics/repair for the front door and body harness connectors listed below. Driver Door 1. Inspect the driver door harness connector (9 or 11 wires depending on vehicle option content) and terminals (inline to body harness). ^ If the connector has 11 leads, then there is no issue. Proceed to Passenger Door. ^ If the connector has 9 leads, then verify that the three empty cavities of the plastic connector are properly blocked. If all three cavities are blocked, then there is no issue. Proceed to Passenger Door. If two cavities are open, then perform the following repair procedure. - If there is no evidence of corrosion, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. - If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors subsection of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (11 wires) and terminals (inline to driver door harness). If there is evidence of corrosion, replace the mating Engine - Broken Bolt Extraction Information Cylinder Head Bolts: Technical Service Bulletins Engine - Broken Bolt Extraction Information INFORMATION Bulletin No.: 05-06-01-026B Date: October 21, 2008 Subject: Information On Torque to Yield Bolt Breakage and Use of Bolt Extractor Tool Kit Part Number EN-47702 for Removing Broken Cylinder Head or Main Bearing Cap Bolts on Inline Truck Engines Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer 2004-2009 Chevrolet Colorado 2002-2009 GMC Envoy 2004-2009 GMC Canyon 2002-2004 Oldsmobile Bravada 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with 2.8L, 2.9L, 3.5L, 3.7L or 4.2L Vortec Inline Engine (VINs 8, 9, 6, E, S - RPOs LK5, LLV, L52, LLR, LL8) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-06-01-026A (Section 06 - Engine/Propulsion System). A Torque To Yield (TTY) bolt, like a cylinder head bolt or main bearing cap bolt, may break during repair procedures. Interaction between a TTY bolt and threads may cause the bolt to bind or break on removal. Prior to removing the cylinder head or main cap bolts, perform the following procedure: Using an appropriately sized punch and hammer, rap on the head of each bolt. The vibration produced by this procedure will assist in successful removal. If a head bolt or main bolt breaks during engine disassembly, a broken bolt extractor kit (EN-47702) has been released to assist in removal of the remaining bolt segment. Many times the remaining bolt segment will back out easily with a pick tool or a reverse twist drill bit. Bolt Replacement & Tightening Important: Never reuse TTY main bearing or cylinder head bolts. Always make sure that the engine block threaded holes are clean and do not place oil or threadlocker on the bolts. Utilize a thread chase tool followed by cleaning with dry compressed air to insure threads are clean and dry prior to installation of new TTY bolts. Bolts that creak and snap while tightening will fail due to excessive torque caused by threads contaminated with debris, antifreeze or oil. Trace amounts of oil or antifreeze will cause this condition. In extreme cases the threads may need additional cleaning with a non-residue cleaner like a brake clean product followed by drying with clean & dry compressed air. Page 10554 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. 9. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 10. Install the tire and wheel center cap. Page 1589 Locations View Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 1394 Electrical Symbols Part 1 Page 10835 For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 15910 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 2667 Malfunction Indicator Lamp (MIL) Inoperative - Steps 8-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Page 10460 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 12660 Electrical Symbols Part 2 Page 1723 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. AWD/4WD System - Delayed Front Wheel Engagement PROM - Programmable Read Only Memory: All Technical Service Bulletins AWD/4WD System Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 3950 Electrical Symbols Part 7 Page 10180 Steering Shaft: Specifications Lower Intermediate Shaft to Power 30 ft. lbs. Steering Gear Input shaft Pinch Bolt Lower Intermediate Shaft to Power Steering Gear Input Shaft Pinch Bolt 29 ft. lbs. Upper Intermediate Shaft to Lower Intermediate Shaft Pinch Bolt 37 ft. lbs. Upper Intermediate Shaft to Steering Column Pinch Bolt 37 ft. lbs. Page 8887 Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake hose bolt from the rear brake caliper. 4. Plug the opening of the brake hose in order to prevent excessive brake fluid loss and contamination. Important: Discard the metal (copper) gaskets. DO NOT reuse metal (copper) gaskets, replace them. 5. Remove the metal (copper) gaskets from the brake hose bolt. 6. Remove the rear brake caliper mounting bolts. Page 15322 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 11667 Electrical Symbols Part 2 Page 5795 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 15831 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 10865 Control Assembly: Service and Repair HVAC System - Manual HVAC Control Module Replacement REMOVAL PROCEDURE 1. Remove the IP accessory trim plate. 2. Remove the control module retaining screws. 3. Depress the HVAC control module retaining tabs (3) and remove the HVAC control module (2) from the instrument panel (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors (1) to the HVAC control module (2). 2. Install the HVAC control module (2) to the instrument panel (4), ensuring that the HVAC control module retaining tabs (3) lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the HVAC control module retaining screws. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 4. Install the IP accessory trim plate. HVAC Control Module Replacement - Auxiliary Page 11303 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 7684 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 1801 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Body - Front Fascia is Loose Front Bumper Cover / Fascia: Customer Interest Body - Front Fascia is Loose File In Section: 08 - Body and Accessories Bulletin No.: 02-08-62-001 Date: August, 2002 TECHNICAL Subject: Front Fascia Loose (Replace Front Fascia Pencil Braces) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22375120 Condition Some customers may comment that the front fascia on the vehicle appears to be loose. This condition may be noticed while the customer is washing the vehicle. Correction Replace the front fascia pencil braces using the following service procedure. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 744862). 2. Remove the lower push-in retainer and the upper bolt from both the right and left front fascia pencil braces. 3. Remove the right and left front fascia pencil braces. 4. Replace the front fascia pencil braces with new pencil braces. Refer to the applicable part numbers listed below. 5. Install and "finger tighten" the upper brace bolts on both sides. 6. Install the lower brace push in retainers on both sides. Tighten Tighten the upper brace bolts to 10 N.m (89 lb in). 7. Lower the vehicle. Page 3105 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. Page 6459 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9768 C201 Part 2 Locations Locations View A/T, Exhaust - Rattling Noise From Under the Vehicle Fluid Line/Hose: All Technical Service Bulletins A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3634 12. Disconnect the radiator side panels from the shroud (1). 13. Remove the radiator. 14. Remove the bolts retaining the condenser to the radiator. Installation Procedure 1. Install the condenser to the radiator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the condenser to the radiator. ^ Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Install the radiator. 4. Install the cooling fan and shroud. 5. Raise the vehicle. Page 12897 4. Drill a 13 mm (1/2 in.) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901MD-01 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. 7. Pass the feed wire (1) through the hinge (2), body pillar (3) and backing plate (4) as shown. 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire (1) while guiding the backing plate (2) into the inner structure. Page 1142 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: Customer Interest Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 176 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 11399 Tighten the center rear seat back mounting nut to 45 N.m (33 lb ft). 6. Return the seat to an upright position. Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (1) securing the center buckles to the mid-position floor latch assembly. 4. Remove the center seat belt buckles. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the center seat belt buckles to the mid-position floor latch assembly with the bolt (1). Tighten Tighten the rear center seat belt buckle assembly bolt to 60 N.m (44 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 1881 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 6119 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 4690 Electrical Symbols Part 2 Page 1884 Various symbols are used in order to describe different service operations. Radio Speakers - Intermittent, Random Noises Speaker: All Technical Service Bulletins Radio Speakers - Intermittent, Random Noises File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-013 Date: October, 2001 TECHNICAL Subject: Noise Heard in Radio Speakers (Replace Amplifier or Repair Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Premium Sound (RPO UQA) This bulletin provides information on two different conditions. Condition 1 Some customers may comment about intermittent static, popping, thumping or booming noises randomly heard in any or all speakers. This condition generally occurs in warmer climate areas. Cause Overheating of the radio amplifier due to ambient and operational temperatures may cause this condition. Correction An improved radio amplifier is now available from GMSPO. Replace the radio amplifier. Refer to the Entertainment sub-section of the Service Manual for the Amplifier Replacement procedure (SI2000 Document ID # 717628). Condition 2 Some customers may comment about consistent static, popping, thumping or booming noises heard in the same speaker repeatedly. Cause This condition may be caused by the radio amplifier wiring harness being pinched by the passenger side rear seat attachments, resulting in damage to the wires. Correction Repair any damaged wires using the procedure listed below. 1. Remove the right rear seat back. Refer to the Seats sub-section of the Service Manual for the Seat Back Replacement procedure (SI2000 Document ID # 741140). 2. Remove the right rear door sill plate. 3. Pull back the carpet in order to access radio amplifier harness. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5835 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 58 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 243 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 1502 Intake Air Temperature (IAT) Sensor Page 7047 Page 5483 Equivalents - Decimal And Metric Part 1 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 12332 Page 4032 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 11786 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 6022 Electrical Symbols Part 6 Page 8182 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 15921 License Plate Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 6509 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 4300 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 12428 Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolt 18 ft. lbs. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 14282 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Page 4877 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12152 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 10657 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the air inlet assembly. 4. Install the screws to the HVAC module assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the HVAC module assembly. 6. Recalibrate the recirculation actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Lighting - Tail Lamp(s) Inoperative Tail Lamp Socket: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the bolt that retains the wheelhouse panel to the rocker panel molding. 2. Remove the 2 screws that retain the wheelhouse panel to the rear fascia. 3. Remove the 4 push-pins retaining the wheelhouse panel to the wheelhouse. 4. Remove the wheelhouse panel from the vehicle. Installation Procedure 1. Install the wheelhouse panel to the vehicle. 2. Install the 4 push-pins retaining the panel to the wheelhouse. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 screws that retain the wheelhouse panel to the rear fascia. Tighten the 2 screw to 2 N.m(18 lb in). 4. Install the bolt that retains the wheelhouse panel to the rocker panel molding. Tighten the bolt to 7 N.m(62 lb in). Page 10131 Equivalents - Decimal And Metric Part 1 Page 5782 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4483 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ......................................................... 1.8 lb. (0.8 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Page 9786 C104 Part 2 C105 C201 Page 9739 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 12150 Electrical Symbols Part 8 Transfer Case Shift Control Module Replacement Control Module: Service and Repair Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Important: The access panel is removed in order to visually see the electrical connectors and the location of the transfer case control module. It will also be easier to see the mounting and alignment slots for the transfer case control module mounting bracket. 1. Remove the access panel. 2. Remove the knee bolster panel. 3. Remove the lower instrument panel cover. AWD/4WD System - Delayed Front Wheel Engagement PROM - Programmable Read Only Memory: All Technical Service Bulletins AWD/4WD System Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 11231 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two or four (if equipped with dual stage air bags) coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when servicing the inflator module. Page 4870 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 4887 Equivalents - Decimal And Metric Part 1 Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6424 Control Module: Service and Repair Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to due so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 5460 Electrical Symbols Part 8 Page 3599 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 1229 Blower Motor Switch - Front Auxiliary Page 9774 C305 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 2949 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt First Pass 110 ft. lbs. Final Pass 180 degrees Page 6495 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Locations View Audio/A/C - Settings Change While Driving Body Control Module: Customer Interest Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14921 Electrical Symbols Part 3 Page 8422 Page 7332 10. Remove the left and right upper ball pinch bolt and nut. 11. Remove the left and right upper shock module retaining nuts. 12. Remove the front stabilizer bar links from the frame. Refer to Stabilizer Shaft Link Replacement in Front Suspension. 13. Remove the shock module from the frame. Page 6258 Transfer Case Actuator: Specifications NVG126-NP4 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) NVG 226-NP8 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) Page 4784 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 8233 2. Align the front output shaft seal on the J 45236-2 (1). 3. Using the J 4523-1 (2), install the front output shaft seal. 4. Remove the J 45236-1 and the J 45236-2. 5. Install the dust shield on the front output shaft. 6. Install the front propeller shaft. 7. Inspect the transfer case fluid level. 8. Install the transfer case shield, if equipped. 9. Lower the vehicle. Refer to Vehicle Lifting. Page 5740 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Audio/A/C - Settings Change While Driving Body Control Module: Customer Interest Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8050 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 5284 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13134 Hood Hinge: Service and Repair Fender Rail Hood Hinge Bracket Replacement - Upper Fender Rail Hood Hinge Bracket Replacement - Upper Removal Procedure 1. Remove all of the related panels and components. 2. Restore as much of the damage as possible to the factory specifications. 3. Note the location and remove the following as necessary: * The sealers * The sound deadeners * The anti-corrosion materials Important: Drill through the hinge bracket only. 4. Locate, and drill out all of the factory welds for installation of the service part. Important: Do not damage any of the inner panels or reinforcements. 5. Remove the damaged hood hinge bracket. Installation Procedure Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Fuse Applications - Underhood Fuse Block Fuse Block: Application and ID Fuse Applications - Underhood Fuse Block Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 14695 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement Removal Procedure 1. Remove the sunroof glass panel. 2. Carefully remove the seal from the perimeter of the glass panel. Installation Procedure 1. Carefully install the seal to the perimeter of the glass panel, ensuring that the seal is fully seated. 2. Install the glass panel to the sunroof. 3. Ensure that the sunroof does not have any air or water leaks. Page 7910 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 5559 Fuel System Diagnosis - Steps 12-17 HVAC Systems - Manual Air Door Actuator / Motor: Diagrams HVAC Systems - Manual Air Temperature Actuator - Auxiliary (Body Type VIN 6) Console Mode Actuator (Body Type VIN 6) Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 8922 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 5818 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 9480 C201 Part 3 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 2207 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14872 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 1465 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 10263 Control Arm: Specifications Rear Axle Lower Control Arm Mounting Bolts 74 ft. lbs. Page 4979 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 10480 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 14430 7. Remove the screws securing the seat cushion trim panel to the seat frame. 8. Remove the seat cushion trim panel. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the screws securing the seat cushion trim panel to the seat cushion assembly. Tighten the rear seat cushion trim panel screws to 2 N.m (18 lb in). 2. Install the seat cover J-strips (1) to the seat cushion trim panel (2). 3. Install the two bolts (2) securing the support (1) to the seat cushion trim panel. Tighten the rear seat support bolts to 35 N.m (26 lb ft). Page 10275 10. Install the outer tie rod to the steering knuckle. 11. Install the outer tie rod retaining nut. Tighten the nuts to 45 Nm (33 ft. lbs.). 12. Install the tire and wheel. 13. Lower the vehicle. 14. Check ten front wheel alignment. Page 15930 1. If replacing the dome lamp bulb (1), install the dome lamp bulb to the socket. 2. If replacing the reading lamp bulb (1), install the reading lamp bulb to the socket. 3. Install the reflector (2) to the dome lamp, ensuring the retaining tabs are fully seated. 4. Position the lens to the headliner with the horizontal tab facing forward. Page 13617 8. Position the inboard retainer (1) to the roof panel. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the inboard retaining screw. Tighten Tighten the screw to 1.2 N.m (10 lb in). 10. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. 11. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 12. Rotate and clip the sunshade to the inboard retainer. 13. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 14. Install the front assist handle to the roof panel. 15. Install the windshield garnish molding. 16. Install the center pillar trim panel. 17. Return the bucket seat to an upright position. Page 8383 Transfer Case Actuator: Specifications NVG126-NP4 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) NVG 226-NP8 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) Page 4247 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Specifications Refrigerant System Capacities Page 5395 Fuel System Diagnosis - Steps 4-11 Page 8469 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 10085 Steering Gear: Service and Repair Power Steering Gear Replacement Power Steering Gear Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Install a drain pan under the vehicle. 3. Remove the tires and wheels. 4. Remove outer tie rods retaining nuts. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 5. Disconnect the outer tie rods from the steering knuckles using J24319-B. Page 4305 Various symbols are used in order to describe different service operations. Page 5535 Page 10702 Locations View - HVAC Systems - Automatic Page 2327 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 1784 Electrical Symbols Part 4 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 6351 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12154 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 4816 Manifold Absolute Pressure (MAP) Sensor Page 969 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Specifications Pressure Regulating Solenoid: Specifications Pressure Control Solenoid Bracket to Valve Body Bolt .............................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 13701 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12786 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13525 11. Remove the bocks from the vehicle. Page 4770 Electrical Symbols Part 4 Page 12610 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 15809 Miniwedge (Door Jamb Switch) - Liftgate Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 2224 Various symbols are used in order to describe different service operations. Page 1757 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10400 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the shock absorber to the shock module. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the shock absorber retaining nut. Tighten the shock absorber retaining nut to 45 Nm (33 ft. lbs.). 5. Remove the shock module (2) from the J45400 (1) 6. Remove the pieces of heater hose from the shock module spring. Page 12998 10. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location on the door according to the service hinge (4). 3. Drill a 3-mm (1/8-in) pilot hole at each location (1). 4. Drill a 13-mm (1/2-in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer Specifications Engine Compartment Fan: Specifications Cooling Fan Nut 41 ft. lbs. Locations Locations View Page 13584 45. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 46. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner and ensure that the retaining strips (1) are engaged, and the headliner harnesses (4) hang free of the headliner. 4. Install the assist handles to the roof panel. 5. Install the right rear push pin (2). 6. Install the left rear push pin (3). 7. Install the 3 push pins in the center of the headliner. 8. Install the sunshades to the headliner. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the left and right sunshade retaining clips (5). Tighten the sunshade retaining clip screws to 10 N.m (88 lb in). Page 5681 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Sunroof Drain Hose Replacement - Front Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Front REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT, Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 3. Remove the 2 hose clips securing the drain hose to the cowl panel, right or left side, as needed. 4. Remove the 2 hose clips securing the drain hose to the side door frame, right or left side, as needed. IMPORTANT: In order to aid in installation, attach a mechanic's wire to the end of the hose. 5. Remove the drain hose from the vehicle, right or left side, as needed. Leave the mechanic's wire behind the instrument panel. INSTALLATION PROCEDURE Page 14392 8. Install the 3 push-pins at the bottom of the rear seat back. 9. Engage the hook and loop retaining strips at the bottom of the rear seat back. 10. Starting at either corner, engage the J strips at the bottom of the rear seat back. 11. Install the head restraints. 12. Install the seat belt bezel to the rear seat back with the plastic retainers (2). Page 2940 Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement Removal Procedure 1. Drain the engine coolant. 2. Remove the PCM. 3. Remove the harnesses from the engine harness bracket. 4. Remove the bolt that secures the engine harness bracket and remove the bracket. 5. Remove the coolant heater cord from the heater (2). 6. Remove the coolant heater from the block. Installation Procedure Page 357 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 13482 Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the front seats. 2. Remove the rear seat cushions. 3. Remove the communication interface module. 4. Remove the navigation control processor bracket. 5. Remove the seat back, left and right side. 6. Remove the front bucket seats. 7. Remove the front door sill plates. 8. Remove the rear door sill plates. 9. Remove the lift gate door sill plate. 11. Remove the lower rear quarter trim panels. 12. Remove the tool kit carrier. 13. Remove the bussed electrical center junction block from the bussed electrical center base, and the bussed electrical center base from the floor panel studs. 14. Remove the child restraint tether anchors. 15. Remove the bussed electrical center base and communication interface module electrical connectors through the pass through holes in the carpet. 16. Remove the floor console to the floor console carrier. 17. Remove the four nuts retaining the rear of the floor console bracket to the floor weld studs. 18. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 19. Remove the carpet from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material Page 15330 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 1716 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Automatic Control Air Door Actuator / Motor: Service and Repair Automatic Control Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the air temperature actuator. 3. Remove the retaining screws from the air temperature actuator. 4. Remove the air temperature actuator (1) from the rear HVAC module. INSTALLATION PROCEDURE 1. Install the air temperature actuator (2) to the rear HVAC module. 2. Install the retaining screws to the air temperature actuator. 3. Connect the electrical connector to the air temperature actuator. 4. Recalibrate the air temperature actuator. Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). 5. Install the right rear quarter trim panel. Left REMOVAL PROCEDURE Page 7260 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 9408 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 1888 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5026 Electrical Symbols Part 5 Spare Tire - Lowering Information Spare Tire Carrier: Technical Service Bulletins Spare Tire - Lowering Information File In Section: 03 - Suspension Bulletin No.: 01-03-10-007 Date: October, 2001 INFORMATION Subject: Information on Lowering Spare Tires Stored Under Vehicle Models: 2002 and Prior Light Duty Trucks with Spare Tire Stored Under Vehicle Spare tires stored under the vehicle are lowered and raised using a vehicle mounted hoist. Operating the hoist at high speed can cause the hoist cable to bind which could make the hoist inoperative. The use of air tools to lower or raise the hoist results in high operating speeds. Important: The hoist should be only lowered and raised by hand using the tools supplied with the vehicle. DO NOT USE AIR TOOLS TO OPERATE THE HOIST. Disclaimer Page 12137 Disclaimer Locations Locations View Page 3086 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: Check the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. ^ Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 107 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 5490 Fuel Injector: Description and Operation Fuel Injectors The fuel injector assembly is a solenoid device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Page 2084 For vehicles repaired under warranty, use the table. Disclaimer Page 9100 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 638 1. Use the J 43244 in order to install the park lamp relay (1) to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. Page 12330 Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 9135 Page 14148 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Page 4685 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 15680 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12484 For vehicles repaired under warranty, use the table. Disclaimer Page 11485 Seat Belt Retractor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Seat Belt Systems / Testing and Inspection. Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Actuator Bolt First pass 18 ft. lbs. Second pass 135° Intake Camshaft Sprocket Bolt First pass 15 ft.lbs. Second Pass 100° Page 1547 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 15002 Fuel Pump And Sender Assembly Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 13695 Door Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 468 Power Seat Control Module: Diagrams Memory Seat Module - Passenger Memory Seat Module - Passenger C1 Locations Page 5945 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13627 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Window Garnish Molding Replacement - Rear Window Removal Procedure 1. Open the liftgate. 2. Release the clips that retain the garnish molding to the liftgate. 3. Remove the wire harness (1) from the slot located on the garnish molding. 4. Remove the garnish molding from the liftgate. Installation Procedure 1. Position the garnish molding to the liftgate. 2. Install wire harness (1) into the slot located on the garnish molding. 3. Index the locating tabs to the corresponding holes in the liftgate. 4. Index the retaining clips to the liftgate. 5. Push the garnish molding into the liftgate in order to fully seat the retaining clips. 6. Close the liftgate. Page 11312 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Page 8375 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3139 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 4119 Disclaimer Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Paint - Chips Behind Front Wheels/Front of Rear Wheels Paint: All Technical Service Bulletins Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Page 14173 2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back cover and pad. 4. Install the front seat head restraint. 5. Install the seat assembly. Head Restraint Cover Replacement - Front Seat REMOVAL PROCEDURE 1. Remove the front seat head restraint. 2. Release the J-strips on the bottom of the head restraint cover. Page 4136 Electrical Symbols Part 7 Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 6132 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 10411 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Tools Required ^ J8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J8001 to a stand. 3. Ensure that the J8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Page 4846 Disclaimer Page 10090 Steering Gear: Service and Repair Rack and Pinion Boot Replacement - Off Vehicle Rack and Pinion Boot Replacement - Off Vehicle Tools Required ^ J22610 Keystone Clamp Pliers Removal Procedure 1. Remove the outer tie rod. 2. Remove the rack and pinion gear. Important: All boot parts must be replaced when replacing the inner tie rod. 3. Remove and discard the small seal retaining clamp (1). 4. Remove and discard the large seal retaining clamp (1) from the rack and pinion boot (2) with side cutters. Important: Do not cut the end of the boot or place a screwdriver between boot and tie rod. Damage to the gear assembly may result. Page 15364 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 14520 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 1 Lumbar Adjuster Switch - Driver (W/Memory Seat) Part 2 Page 4242 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 6500 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Page 4418 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 14270 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Rear Motor (W/Memory Seat) Page 5069 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Page 11476 3. If both the driver and passenger front safety belts lock when performing the inspection, no further action is required. If any of the seat belts did not lock up, refer to the Seat Belt Retractor Replacement Procedure, and replace the applicable retractor. Seat Belt Retractor Replacement Important The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information. Important For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Important Do not remove the seat from the vehicle when performing the following procedure. 1. Remove the SIR fuse. 2. Disconnect the side impact air bag electrical connector located under the seat. 3. If equipped, remove the lumbar knob and/or seat back recliner screw and handle. 4. Remove the screws attaching the seat switch bezel and reposition the bezel. 5. Remove the outer trim panel attaching screws and remove the panel from the side of the seat cushion. Page 1686 Accelerator Pedal Position (APP) Sensor Assist Step Support Bracket Replacement Auxiliary Step / Running Board: Service and Repair Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Remove the bolts that retain the assist step support brackets to the body. 2. Remove the assist step assembly from the vehicle. 3. Place the step assembly on a clean, prepared surface. 4. Remove the nuts (1) that retain the assist step to the support brackets. 5. Remove the support brackets from the assist step. Installation Procedure 1. Position the assist step to the support brackets. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (1) that retain the assist step to the support brackets. Tighten the nuts to 25 N.m (18 lb ft). Page 15291 For vehicles repaired under warranty, use the table. Disclaimer Page 3481 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 6732 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 7335 22. Remove the oil pan. Refer to Oil Pan Replacement in 4.2L Engine Mechanical. 23. Remove the front drive axle from the vehicle. Installation Procedure 1. Install the front drive axle to the frame. 2. Secure the front drive axle to the frame. 3. Install the oil pan. Refer to Oil Pan Replacement in 4.2L Engine Mechanical. 4. Remove the front drive axle from the frame. 5. Install the front drive axle to the oil pan. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the front drive axle mounting bolts. Tighten Tighten the front drive axle mounting bolts to 85 N.m (63 lb ft). Page 8072 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 7454 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Tools Required ^ J8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J8001 to a stand. 3. Ensure that the J8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Page 12539 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 10883 Locations View - HVAC Systems - Automatic Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 7211 Disclaimer Diagrams Power Door Lock Actuator: Diagrams Door Lock Actuator - Driver Door Lock Actuator - LR Front Door Window Belt Outer Front Door Window Glass Weatherstrip: Service and Repair Front Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten Tighten the screw to 1.2 N.m (10 lb in). Page 12483 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 15161 Oil Pressure Sender: Specifications Oil Pressure Sensor 15 ft. lbs. Page 6035 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 15032 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Engine Controls - SES Lamp ON/ DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/ DTC's Set On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) # 04032 - (05/13/2004) 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 -Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the power train control module (PCM) on all affected vehicles as identified above including vehicles in new dealer inventory used inventory and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 5334 Various symbols are used in order to describe different service operations. Page 12743 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. Page 14358 15. Spread the pad apart and push the cover and pad up over the seat back in order to expose the head restraint guides. 16. Remove the head restraint guides by squeezing the locking tabs together and pulling the restraint guides upward and out of the seat frame. 17. Remove the seat back cover the remainder of the way from the seat back. 18. Disconnect the electrical connector for the seat back heating element, located near the seat belt retractor, if equipped. 19. Carefully remove the seat back pad from the seat back frame. INSTALLATION PROCEDURE 1. Position the seat back pad to the seat back frame. 2. Connect the electrical connector to the seat back heating element, if equipped. 3. Partially install the seat back cover over the top of the seat. 4. Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The guide with the release tab goes on the right-hand side. Page 3145 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 798 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 11684 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12046 Electrical Symbols Part 7 Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the 2HI position. 1. Raise the vehicle. 2. Remove the fuel tank shield, if equipped. 3. Disconnect the motor/encoder electrical connector (1). 4. Remove the motor/encoder mounting bolts. Page 11262 Side Air Bag: Diagrams Inflatable Restraint Side Impact Module - Left Inflatable Restraint Side Impact Module - Right Page 9508 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 8981 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear brake caliper on the mounting bracket. ^ Tighten the brake caliper mounting bolts to 31 Nm (23 ft. lbs.). 6. Install the NEW metal (copper) gaskets on the brake hose bolt. 7. Remove the plug from the brake hose end. 8. Install the brake hose bolt on the rear brake caliper. ^ Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 5162 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Page 5032 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Fuse Block - Rear Locations View Diagrams Seat Heater Sensor: Diagrams Heated Seat Element - Driver Cushion Heated Seat Element And Thermistor Assembly - Driver Back Page 10935 Evaporator Core: Service and Repair Evaporator Core Replacement REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair IMPORTANT: Some screws are hidden under the foam insulation. 2. Remove the screws to separate the HVAC module assembly halves. 3. Separate the HVAC module assembly (1). 4. Remove the evaporator core (2) from the HVAC module assembly (1). 5. Remove the seal between the HVAC module assembly halves. INSTALLATION PROCEDURE IMPORTANT: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities (fart) for system capacity information. 1. Install the seal between the HVAC module assembly halves. 2. Install the evaporator core (2) to the HVAC module assembly (1). IMPORTANT: Ensure that the seal between the two case sections is in place. 3. Assemble the HVAC module assembly. Page 136 Page 3944 Electrical Symbols Part 1 Page 14016 For vehicles repaired under warranty, use the table. Disclaimer Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 5062 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 3977 Conversion - English/Metric Page 9895 43. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 44. Turn the key OFF. Remove the key. 45. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 46. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 47. Reinstall the rear electrical center cover. 48. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 49. Reinstall the knee bolster (TrailBlazer). 50. Reinstall the closeout/insulator panel (TrailBlazer). 51. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 52. Reinstall the console to the vehicle and install the retainers. 53. Reinstall the shift boot and handle assembly. 54. Reinstall the console bin and retainers. 55. Reinstall the first lock pillar trim and carpet retainers to both door openings. 56. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 57. Install the IP upper trim panel and windshield pillar moldings. 58. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 59. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios With Rear Audio Controls These vehicles use wiring harness P/N 15164933. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. Page 15314 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14246 Power Seat Control Module: Description and Operation MEMORY SEAT MODULE (DSM) Battery positive voltage is supplied through the seat circuit breaker to the DSM. In response to a valid manual or memory switch command, the DSM will apply power and ground to the selected motors within 150 ms. To limit peak power, DSM restricts the number of motors that can be turned on simultaneously to three motors. If the module detects all four switches at the same time, DSM turns on three seat adjusters: horizontal, front, and rear. If the user continues to hold all four switches, the DSM actuates the fourth motor only after one of the first three motors has reached its end motion. For a memory recall operation, the DSM first moves the horizontal, front, and rear motors first. If all four switches are still activated, DSM actuate the recline motor only when one of the seat adjusters has reached its end motion. In order to conserve battery power, the DSM enters automatic standby mode whenever the unit has been inactive for 16 seconds. In the standby mode, the DSM stores memory settings so that when it is awake again it knows where the seat is set. Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 6479 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 13245 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10499 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 9455 C101 Part 1 Page 9300 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3053 Engine Mount: Service and Repair Engine Mount Inspection Engine Mount Inspection Front Engine Mount Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Install a pole jack underneath the oil pan. 2. Insert a block of wood between the engine oil pan and the pole jack. 3. Raise the jack until the wooden block contacts the engine oil pan. 4. Raise the engine in order to place a slight tension on the rubber cushion. Observe both mounts while raising the engine. 5. Replace the mounts if any of the following conditions exist: ^ Hard rubber surface covered with heat check cracks ^ The rubber cushion separated from the metal plate of the mount ^ The rubber cushion is split through the center 6. If there is movement between a metal plate of the mount and its attaching points, lower the engine and tighten the bolts or nuts attaching the mount to the engine, the frame or the bracket. Page 1707 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9799 C311 C312 Part 1 Page 14410 1. Release the J-strips that retain the cover to the seat pan. 2. Compress the foam and partially remove the seat cover assembly from the seat pan. IMPORTANT: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 3. Remove the cover from the cushion by separating the retaining strips. 4. Separate and remove the cushion and cover assembly from the seat pan. 5. Release the reinforcement bar from the hog-rings. 6. Remove the cover from the cushion. INSTALLATION PROCEDURE 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. Seat Cushion Cover and Pad Replacement - Rear No. 2 REMOVAL PROCEDURE Locations Locations View Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 4853 Oxygen Sensor: Locations Locations View Page 7607 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 12928 6. Install the rearward trim panel retaining bolt second. 7. Tighten the two retaining bolts. Notice: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 10 N.m (88 lb in). 4. Install the accessory switch panel. Electrical - Intermittent Multiple Malfunctions Multiple Junction Connector: Customer Interest Electrical - Intermittent Multiple Malfunctions File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-017 Date: August, 2002 TECHNICAL Subject: No Start, Service Engine Soon Lamp On, ABS Warning Light On, Air Bag Light On, DTCs Set, Various Door Electrical Functions Inoperative (Replace Driver and/or Passenger Door Harness and/or Repair Body Harness Connector) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT, TrailBlazer Export 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Built Prior to April, 2002 Condition Some customers may comment that the vehicle will not start and/or any of the following door electrical functions may be inoperative: ^ Power Door Locks ^ Outside Mirrors ^ Memory Seat ^ Power Windows ^ Heated Front Seats ^ Door Audio Speaker ^ Liftgate Some may comment that these conditions occur intermittently. Diagnosis of these conditions may also find that various Diagnostic Trouble Codes (DTCs) may be set. Cause Moisture intrusion through the passenger side and driver side front door-to-body harness inline connections. Correction Follow the recommended diagnostics/repair for the front door and body harness connectors listed below. Driver Door 1. Inspect the driver door harness connector (9 or 11 wires depending on vehicle option content) and terminals (inline to body harness). ^ If the connector has 11 leads, then there is no issue. Proceed to Passenger Door. ^ If the connector has 9 leads, then verify that the three empty cavities of the plastic connector are properly blocked. If all three cavities are blocked, then there is no issue. Proceed to Passenger Door. If two cavities are open, then perform the following repair procedure. - If there is no evidence of corrosion, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. - If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors subsection of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (11 wires) and terminals (inline to driver door harness). If there is evidence of corrosion, replace the mating Page 4198 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Memory Seat Module - Driver Power Seat Control Module: Diagrams Memory Seat Module - Driver Memory Seat Module - Driver C1 Page 14788 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Diagrams Hood Ajar Switch (Export) Page 11734 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 10223 Ball Joint: Specifications Upper Ball Joint Pinch Bolt 30 ft. lbs. Wear Limit See Note If you find any looseness or can twist the upper ball joint stud with your fingers, replace the upper control arm. Page 14882 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 2215 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 3607 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 6056 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Page 7739 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Page 6493 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 9778 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 4580 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11364 5. Install the anchor bolt cover. 6. Install the rear quarter upper trim, left or right side. 7. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt upper guide bolt to 70 N.m (52 lb ft). Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the left rear quarter trim panel. 3. Remove the lower seat belt anchor bolt cover. 4. Remove the rear seat belt floor anchor bolt. 5. Remove the bolt that retains the rear seat belt retractor assembly to the body. 6. Remove the rear seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the rear seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the rear seat belt retractor assembly to the body. Tighten Page 5229 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 15612 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 10971 1. Install the heater core-auxiliary (2) to the HVAC module-auxiliary. 2. Install the HVAC module pass thru seal-auxiliary. 3. Install the heater core access cover-auxiliary (3) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core access cover-auxiliary (3). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the rear HVAC module-auxiliary. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement - Auxiliary Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 3437 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test ^ Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: ^ When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. ^ When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. ^ When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. ^ When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 1467 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12179 Speaker - RF I/P (W/UQA) Speaker - RR Door For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Diagrams Timing Chain Alignment Diagram Page 1300 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 12454 Page 13799 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 12324 Page 5799 Various symbols are used in order to describe different service operations. Page 10639 Recirculation Actuator Mode Actuator - Auxiliary (Body Type VIN 3) Page 15843 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13582 25. Peel the carpet forward and up over the front seats. Note that the carpet hooks around the wheel house panel stud. 26. Remove the headliner harness from the left-hand third pillar. 27. Remove the headliner harness from the floor studs. 28. Remove the third pillar headliner harness electrical connector from the body electrical block, and the block base from the floor panel. 29. Reach underneath the carpet and disconnect the 6-way headliner harness electrical connector (1) from the cross-body wire harness. 30. Remove the navigational antenna cable from the right-hand third pillar. 31. Remove the navigational antenna cable from the floor studs. 32. Pull the communication interface module electrical connectors back through the hole in the carpet. 33. Remove the cellular antenna coax cable from the inner coupling on the left body side window. Page 15355 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 8886 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the front brake caliper to the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front brake caliper mounting bolts. ^ Tighten the front brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Important: DO NOT reuse the metal/copper gaskets. Use only new metal/copper gaskets. 6. Install the NEW metal/copper gaskets to the front brake caliper bolt. 7. Install the front brake hose bolt and gaskets. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Rear Brake Caliper Replacement - Rear Page 11594 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7719 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 14423 1. Install the seat cushion panel on the pad and cover. 2. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 3. Install the pull handle (1). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two rear seat cushion bolts (2). Tighten Tighten the rear seat cushion bolts to 11 N.m (97 lb in). Page 6030 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 4997 Powertrain Control Module (PCM) C2 Part 1 Specifications Luggage Rack: Specifications Fastener Tightening Specifications Page 8933 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 12999 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). 8. Hand tighten the 4 supplied bolts (4). Notice: Refer to Fastener Notice in Service Precautions. 9. Align the hinge to the original scribe location. Tighten the bolts to 25 N.m (18 lb ft). 10. Clean and prepare all bare-metal surfaces. 11. Apply a full-bodied caulk around the service hinge. 12. Refinish as necessary. 13. Install and align all of the related panels and components. Locations Service Port HVAC: Locations A/C SERVICE PORTS The Low Side Service Port is located on the A/C Accumulator. The High Side Service Port is located on the High Pressure Liquid Line. Page 3855 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Specifications Fuel Level Specifications A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 5303 Electrical Symbols Part 2 Page 2883 Notice: Refer to Fastener Notice in Service Precautions. 7. Install the camshaft caps onto their original journal. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 10. Install the camshaft cover. Page 4704 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 13100 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. INSTALLATION PROCEDURE 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Rear Door Opening REMOVAL PROCEDURE Page 13966 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5663 IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm. 2. Install the fuel sender assembly into the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Use the J 44402 to install the fuel sender assembly retaining ring. 4. Install the fuel tank. Page 1645 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5820 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 12301 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 4691 Electrical Symbols Part 3 Page 3630 For vehicles repaired under warranty, use the table. Disclaimer Page 13946 Electrical Symbols Part 5 Page 14365 5. Install the seat cover the remainder of the way. 6. Engage the seat cover to the hook and loop retaining strips on the seat back pad. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the screw that retains the rear seat back release latch bezel to the rear seat back. Tighten Tighten the rear seat back release latch bezel screw to 3 N.m (26 lb in). Page 3245 Conversion - English/Metric Page 15481 Conversion - English/Metric Page 6821 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 948 For vehicles repaired under warranty, use the table. Disclaimer Page 2664 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Page 747 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 12057 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 6870 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 3501 For vehicles repaired under warranty, use the table. Disclaimer Page 5698 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 9893 58. Install the IP upper trim panel and windshield pillar moldings. 59. Reinstall the SIR fuse #18 in the underhood electrical center and close the hood. 60. Connect the Tech 2(R) and clear codes. Bose(R) Premium Sound Without Rear Audio Controls These vehicles use wiring harness P/N 15164931, which you will modify slightly by cutting some unused wires. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove the shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconnect the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). 22. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. Important: Page 13974 Various symbols are used in order to describe different service operations. Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Speaker Replacement - Front Door Speaker: Service and Repair Speaker Replacement - Front Door REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the speaker electrical connector. 3. Remove the 3 speaker retaining bolts. 4. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Install the speaker to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 speaker retaining bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the speaker electrical connector. 4. Install the front door trim panel. Page 15663 Electrical Symbols Part 1 Page 1472 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3136 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 3336 Timing Cover: Specifications Engine Front Cover Bolt 89 inch lbs. Engine Front Cover Spacer Bolt 89 inch lbs. Page 7263 Page 582 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 12178 Speaker - LF I/P (W/UQA) Speaker - RF Door Page 155 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 15907 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 15586 Electrical Symbols Part 2 Page 12689 Equivalents - Decimal And Metric Part 1 Page 2653 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 11976 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 8883 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. ^ Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. Page 186 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 3845 Electrical Symbols Part 4 Page 817 Equivalents - Decimal And Metric Part 1 Page 13407 Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Rear Steering Gear Crossmember Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front steering gear crossmember rear mounting bolts. 3. Remove the rear steering gear crossmember mounting bolts. 4. Remove the rear steering gear crossmember from the vehicle. Installation Procedure 1. Install the rear steering gear crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear steering gear crossmember mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the front steering gear crossmember rear mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 4. Lower the vehicle. Page 13752 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. NOTE: Refer to Fastener Notice in Service Precautions. Page 13268 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Page 4586 Various symbols are used in order to describe different service operations. Page 5000 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - 1 The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. POWERTRAIN CONTROL MODULE (PCM) - 2 The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 10079 Steering Gear: Specifications Power Steering Gear to the Frame Mounting Bolts 81 ft. lbs. Page 2512 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ....................................................................................................... 5W-30 (preferred), 10W-30 if over 0° F Page 15477 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 2871 4. Install the J-44217 (1). 4.1 Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. 4.2 Tighten the wingnuts. 4.3 Ensure the hooks are still in one of the links and the gauge blocks of the tool are firmly in place on the edge of the head. 5. Remove the exhaust camshaft position actuator bolt. 6. Remove the exhaust camshaft position actuator. Installation Procedure Page 10416 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. 9. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 10. Install the tire and wheel center cap. Page 466 Memory Seat Module - Driver C2 Memory Seat Module - Driver C3 Page 4070 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 4545 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Transfer Case Output Shaft Seal Replacement - Front (Trailblazer, Envoy) Seals and Gaskets: Service and Repair Transfer Case Output Shaft Seal Replacement - Front (Trailblazer, Envoy) Transfer Case Output Shaft Seal Replacement - Front (Trailblazer, Envoy) ^ Tools Required J 45236 Output Shaft Seal Installer - Front Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the front propeller shaft. 4. Remove the dust shield from the front output shaft. 5. Lightly tap the screw driver around the edge of the front output shaft seal. Page 3240 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Description and Operation Knee Diverter: Description and Operation KNEE BOLSTER The Knee Bolsters are designed to help restrain the lower torso of front seat occupants by absorbing the energy through the front seat occupant's upper legs. In a frontal collision the front seat occupant legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform, absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damages after a collision. Page 5518 Page 11954 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 5389 4. Tighten the throttle body clamps (2). Tighten the clamps to 4 Nm (35 lb in) 5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator. 6. Lubricate the inner diameter of the crankcase ventilation hose. 7. Connect the crankcase dirty air hose to the intake manifold. 8. Connect the crankcase dirty air hose to the PCV orifice tube. Page 12052 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 10740 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5787 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14652 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Page 6792 ^ Scoring ^ Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. Interior - Front Floor Carpet Is Wet Carpet: Customer Interest Interior - Front Floor Carpet Is Wet TECHNICAL Bulletin No.: 03-08-57-004D Date: November 21, 2008 Subject: Front Floor Carpet Wet (Seal Top of "A" Pillar) Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2009 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-08-57-004C (Section 08 - Body and Accessories). Condition Some customers may comment that the front floor carpet is wet. Cause 1 Water may enter a hole in the seam sealer at the roof panel to upper "A" pillar post. In this case, the water enters the hole and leaks down the inside of the "A" pillar and ends up on the front floor. Refer to the illustration above. Cause 2 Water may enter the seam at the top of the "A" pillar. In this case, the water enters where the roof panel to upper "A" pillar meet and follows this seam under the windshield urethane. The water then drips onto the "A" pillar garnish molding and ends up on the floor. Refer to the illustration above. Cause 3 Page 238 HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: All Technical Service Bulletins HomeLink(R) Transmitter Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Page 9779 C311 C312 Part 1 Page 9686 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14977 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 11621 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Rear Door Window Belt Outer Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten Tighten the screw to 1.2 N.m (10 lb in). Page 180 Parts Information Page 7081 Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 10999 11. Disconnect the electrical connectors from the HVAC module. 12. Disconnect the rear compartment air outlet ducts (5) from the HVAC module (3). 13. Remove the mounting bolts (5) from the HVAC module. 14. Remove the HVAC module (1). 15. Remove and discard the HVAC module pass through seal. INSTALLATION PROCEDURE Page 13033 Page 11920 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 6044 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 15723 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 8552 For vehicles repaired under warranty, use the table. Disclaimer Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 9492 C314 C315 Part 1 Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Page 5560 Fuel System Diagnosis - Steps 18-22 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, then an internal loss of pressure is indicated. 7. This step inspects the fuel pressure regulator for a fuel leak from the atmospheric vent. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 8. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 9. This step tests for a leaking fuel injector or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 12. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 14. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 16. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Page 13089 Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) Page 127 Circuit/System Testing Component Testing Page 7728 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5599 Various symbols are used in order to describe different service operations. Page 11851 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 6725 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 8012 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Page 281 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1885 Conversion - English/Metric Page 13626 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Page 1607 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 3187 During the 2004 model year, there was a design change made to the engine oil pick up tube and the front cover as shown. The first design parts used in production for 2002, 2003 and part of 2004 model year used an 0-ring type seal between the pick up tube and the front cover. The second design parts began production during the 2004 model year and use a face type seal. Anytime the front cover or oil pick up tube are being serviced, be sure to identify which design is being serviced. The correct pick up tube must be used with its corresponding front cover or an engine failure could result. Any vehicle requiring a new front cover must be serviced with the second design front cover, therefore, the engine oil pick up tube must be replaced at the same time. Disclaimer Fuse Block - Rear Fuse Block: Locations Fuse Block - Rear Fuse Block Rear Locations View Located under the left rear seat. Page 1017 4. Remove the three push-in retainers that attach the air inlet grille (leaf screen) to the plenum sheet metal. 5. Lower the hood to the secondary latch. 6. Using a suitable marker or masking tape, mark the location of both wiper blades on the windshield. 7. Remove the covers from the nuts that attach the wiper arms. 8. Remove the nuts from the wiper arms. Important If the rocking action in the next step fails to loosen the wiper arm, it may be necessary to use a standard top-post battery cable terminal puller to remove the wiper arm. 9. Rock the wiper arms back and forth to loosen and remove them from the wiper transmission shaft. 10. Remove the antenna mast. 11. Remove the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. 12. Remove the air inlet grille and reposition it up to the windshield. It is not necessary to disconnect the washer hose. 13. Remove the two 10 mm hex head bolts that attach the wiper module to the plenum sheet metal. 14. Disconnect the electrical connector. 15. Remove the wiper module and place on a suitable work surface. Recall 01V334000: Transfer Case Control Module Update PROM - Programmable Read Only Memory: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 1785 Electrical Symbols Part 5 Page 8895 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the lower mounting bolt from the slide pin. 8. Rotate the brake caliper upward until it stops. Page 384 Electrical Symbols Part 8 Interior - Power Memory Seat Inoperative Power Seat Control Module: All Technical Service Bulletins Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 12453 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 15851 Turn Signal/Hazard Flasher Module Page 10694 4. Seat the left side of the air outlet to the housing retaining pin. 5. Rotate the air outlet upward past the detent position. 6. Adjust the air outlet to the original position. Page 12950 Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) Page 444 Disclaimer Page 16010 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 11428 Page 5378 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vent Pipe) REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. EVAP Vent Valve 1. Remove the fuel tank 2. Disconnect the evaporative emission (EVAP) vent pipe (3) from the EVAP canister vent valve (1). 3. Remove the EVAP vent pipe from the fuel tank retainers. INSTALLATION PROCEDURE EVAP Vent Valve 1. Install the EVAP vent pipe to the fuel tank retainers. 2. Connect the EVAP vent pipe (3) to the EVAP canister vent valve (1). 3. Install the fuel tank. Page 15426 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 11140 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Right REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2) INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Page 1728 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4343 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 5840 Various symbols are used in order to describe different service operations. Page 14059 Power Seat Control Module: Diagrams Memory Seat Module - Passenger Memory Seat Module - Passenger C1 Page 15395 Electrical Symbols Part 4 Page 8223 5. Install the lower instrument panel cover. 6. Install the knee bolster panel. 7. Install the access panel. 8. Program the transfer case shift control module. Page 5932 Electrical Symbols Part 6 Page 3553 1. Apply coolant to the end of the heater inlet hoses. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. 3. Install the coolant bypass valve (6). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nut retaining the coolant bypass valve to the cowel. Tighten Tighten the nut to 10 N.m (89 lb in). 5. Install the vacuum hose to the coolant bypass valve. 6. Install the inlet heater hose to the engine block. 7. Position the inlet heater hose clamp at the engine block using J 38185. 8. Connect the heater inlet hose to the heater core. IMPORTANT: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 9. Install the coolant recovery reservoir. 10. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 730 Locations View Page 13630 2. Release the clips that retain the garnish molding to the liftgate. 3. Remove the wire harness (1) from the slot located on the garnish molding. 4. Remove the garnish molding from the liftgate. Installation Procedure 1. Position the garnish molding to the liftgate. 2. Install wire harness (1) into the slot located on the garnish molding. 3. Index the locating tabs to the corresponding holes in the liftgate. 4. Index the retaining clips to the liftgate. 5. Push the garnish molding into the liftgate in order to fully seat the retaining clips. 6. Close the liftgate. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Starting at the top of the garnish molding, carefully release the upper attaching clip that retains the garnish molding to the first pillar. 2. Release the remaining 2 retaining clips from the first pillar. 3. Remove the garnish molding (1) from the vehicle. Installation Procedure Page 15407 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 3873 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 5325 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 15198 Page 1695 Electrical Symbols Part 2 Page 11765 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 3084 IMPORTANT: When adding to, or changing the engine oil, use ONLY oils of the proper quality. In countries other than the United States and Canada, it may be difficult to find engine oils that display the API STARBURST symbol certifying the oil is for use in gasoline engines. If you are unable to find engine oils displaying the API STARBURST symbol, use engine oils that meet API Service SJ and/or ACEA A1-96, ACEA A2-96, or ACEA A3-96 requirements as shown in the chart. Page 9283 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 9485 C305 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 1328 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 2766 Disclaimer Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 11905 Page 6978 1. Install a new seal (2) into the transmission case. 2. Install the filler tube (1) into the seal. 3. Remove the drain pan. 4. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the nut (2) securing the filler tube to the exhaust manifold stud (1). ^ Tighten the nut to 10 Nm (89 inch lbs.). 6. Install the filler tube indicator. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. Page 15754 1. Install the bulb to the socket. 2. Install the trim panel to the IP. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 5 screws that retain the IP compartment jamb trim panel to the IP. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Position the socket assembly to the trim panel and connect the electrical connector. 5. Install the socket assembly to the trim panel. Verify that the retaining tabs are fully seated. 6. Close the IP compartment. Page 11789 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 7657 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 1147 Page 2401 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON- III transmission fluid. Refer to Transmission Fluid Checking Procedure. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 14785 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 6159 Disclaimer Page 10805 Condenser HVAC: Service and Repair TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the upper radiator baffle. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Remove the compressor discharge hose nut (1) from the condenser (4). 4. Remove the compressor discharge hose (2) from the condenser (4). 5. Remove the evaporator tube nut (5) from the condenser (3). 6. Remove the evaporator tube (4) from the condenser (3). 7. Remove the radiator. 8. Remove the retaining screws from the condenser. 9. Remove the condenser from the radiator. INSTALLATION PROCEDURE IMPORTANT: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities (fart) for the capacity information. Page 3077 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 1569 Disclaimer Page 7640 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 1133 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the left coat hook. NOTE: In order to avoid damaging the antenna lead connector, follow these guidelines: Use a plastic tool and carefully pry the connector from the window. - Do NOT pull on the connector, which may be stuck to the urethane adhesive or the headliner. 2. Disconnect the radio antenna module electrical connector from the stationary glass. 3. Release the rear headliner to roof retainers. 4. Lower the rear of the headliner far enough to access the radio antenna module located on the left side of the vehicle. 5. Disconnect the electrical connector from the radio antenna module. 6. Disconnect the coax cable from the radio antenna module. 7. Remove the radio antenna module from the headliner retaining strips. 8. Remove the radio antenna module from the vehicle. INSTALLATION PROCEDURE Page 5004 Engine Control Module: Service and Repair Powertrain Control Module Programming and Setup BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel - Interior lights - Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. - Heating, ventilation, and air conditioning (HVAC) systems - Engine Cooling fans etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. Do NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. - All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2(TM) to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2(TM), select Service Programming. 6. Identify vehicle information as requested by the Tech 2(TM) 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline(TM) terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2(TM) and disconnect the Tech 2(TM) from the vehicle 12. Turn OFF the ignition. 13. Connect the Tech 2(TM) to the Techline(TM) terminal. 14. Select Service Programming. 15. Select Tech 2(TM) as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. - Normal-This type of programming is for updating an existing calibration or programming a new controller. - Vehicle configuration Index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline(TM) terminal. Observe, you will need to contact the Techline(TM) Customer Support center to use this option. - Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2(TM). 23. After the download is complete, turn OFF the Tech 2(TM). 24. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 25. Install the Tech 2(TM) to the data link connector (DLC). 26. Turn ON the Tech 2(TM). 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Front Inside Front Door Interior Handle: Service and Repair Front Inside REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the handle retaining bolt. 3. Release the handle locator tab from the locator cutout, by sliding the handle forward. 4. Release the rod retainer locks. 5. Remove the rods from the handle. 6. Remove the handle from the door. INSTALLATION PROCEDURE 1. Position the handle to the door. 2. Install the rods to the handle. 3. Install the rod retainer locks. 4. Insert the handle locator tab into the locator cutout and move the handle rearward, indexing the fastener hole to the door. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the handle retaining bolt. Tighten Tighten bolt to 10 N.m (88 lb in). 6. Install the door trim panel. Page 12093 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Page 15732 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 12355 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 13911 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Specifications Brake Master Cylinder: Specifications Brake Master Cylinder Mounting Bolts 27 ft. lbs. Page 15296 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 6248 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 12774 2. Position the assist step assembly to the vehicle. 3. Install the bolts that retain the support brackets to the body. Tighten the bolts to 25 N.m (18 lb ft). Page 8386 Page 14756 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 763 Equivalents - Decimal And Metric Part 1 Page 9477 C104 Part 2 C105 C201 Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Driver Door Module (DDM) Locations View Page 14839 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 8604 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 9371 Fuse Block - Underhood C2 Part 2 Page 14386 10. Using a flat-bladed tool, carefully engage the plastic strips that retain the seat back cover to the side airbag inflator module. 11. Carefully install the seat back cover behind the trim edge of the side airbag inflator module. 12. Fasten the J-strips (1, 4) across the bottom of the seat back cover. 13. Install the seat cover flaps (2) to the seat frame with push pins (3). 14. Install the seat trim panel. 15. Install the head restraint. 16. Install the front seat assembly from the vehicle. Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE Page 4731 Engine Control Module: Service and Repair Powertrain Control Module Programming and Setup BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel - Interior lights - Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. - Heating, ventilation, and air conditioning (HVAC) systems - Engine Cooling fans etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. Do NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. - All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2(TM) to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2(TM), select Service Programming. 6. Identify vehicle information as requested by the Tech 2(TM) 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline(TM) terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2(TM) and disconnect the Tech 2(TM) from the vehicle 12. Turn OFF the ignition. 13. Connect the Tech 2(TM) to the Techline(TM) terminal. 14. Select Service Programming. 15. Select Tech 2(TM) as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. - Normal-This type of programming is for updating an existing calibration or programming a new controller. - Vehicle configuration Index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline(TM) terminal. Observe, you will need to contact the Techline(TM) Customer Support center to use this option. - Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2(TM). 23. After the download is complete, turn OFF the Tech 2(TM). 24. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 25. Install the Tech 2(TM) to the data link connector (DLC). 26. Turn ON the Tech 2(TM). 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Page 13982 Front Passenger Door Module (FPDM) C3 Page 10124 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4571 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3622 Conversion - English/Metric Page 10509 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 8741 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 15775 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 1948 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 10713 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Left REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Page 9231 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3605 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3867 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4758 Scan Tool Does Not Communicate With Class 2 Device - Steps 1-9 Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the front brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. 6. Remove the front brake pads from the mounting bracket, inboard brake pad shown. 7. Inspect the brake hardware. Locations Locations View Page 14654 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 6321 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Diagrams Hood Ajar Switch (Export) Page 6623 Disclaimer Page 3020 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 4754 Information Bus: Description and Operation General Description CIRCUIT DESCRIPTION The Data Link Connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for Diagnostic Trouble Codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a State Of Health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the Inflatable Restraint Sensing And Diagnostic Module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Class 2 serial data at terminal 2. - Common signal ground at terminal 5. CLASS 2 SERIAL DATA LINE The class 2 serial data line on this vehicle is a ring/star configuration. The BCM and PCM form the ring portion of the class 2 serial data circuit. If one of the class 2 serial data circuits to the BCM or PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The Body Control Module (BCM) - The Driver Door Module (DDM) - The Electronic Brake Control Module (EBCM) - The Front Passenger Door Control Module (FPDM) - The HVAC control module - The inflatable restraint sensing and diagnostic module (SDM) - The Instrument Panel Cluster (IPC) - The Liftgate Control Module (LGM) - The memory seat module-driver W/power seat - The memory seat module-passenger W/power seat - The Powertrain Control Module (PCM) - The radio - The radio amplifier - The RSA/HVAC control module-rear auxiliary - The theft deterrent control module W/Immobilizer - The transfer case shift control module W/4WD - The Vehicle Communication Interface Module (VCIM) W/UE1 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via two splice packs and a data link connector (DLC): SP205 Located behind the I/P near the headlamp switch connector. - SP206 Located in the body harness near the rear of the right rear seat under the carpet. - DLC connects the scan tool to the class 2 serial data circuits. Refer to Data Link Communications Component Views. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 9211 Electrical Symbols Part 6 Page 15677 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 2393 Disclaimer Locations Wiper Switch: Locations Locations View Page 11223 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 7479 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement- Rear Propeller Shaft Replacement- Rear Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts and the yoke retainers from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft. Installation Procedure HVAC Systems - Manual Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Page 13881 For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 5727 Electrical Symbols Part 5 Page 11956 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 644 Locations View Page 9728 For vehicles repaired under warranty, use the table. Disclaimer Page 6850 Channel Plate: Specifications Plate to Case Bolt (Shipping) ................................................................................................................................................... 27.0-34.0 Nm (20-25 ft. lbs.) Plate to Converter Bolt (Shipping) ........................................................................................................................................... 27.0-34.0 Nm (20-25 ft. lbs.) Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 7053 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Rear Axle ............................................................................................................................................. .................................................. 1.9 Liters (4.0 Pints) Rear Axle w/8.6" ring gear .............................. .................................................................................................................................... 2.28 Liters (4.8 Pints) Front Differential Front Axle ............................................................................................................................................ ................................................. 0.8 Liters (1.7 Pints) Page 15406 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 7447 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 14052 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2626 Fuse Block - Underhood C2 Part 1 Page 12552 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 5997 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10534 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 8932 Important: It maybe necessary to readjust the park brake shoes to allow the brake rotor to be reinstalled. 4. Adjust the park brake shoe (1). Important: Ensure that the rotor to axle flange relationships marks are aligned, if the brake rotor has been refinished, after the brake rotor is installed. 5. Install the brake rotor by slowly turning the rotor while pushing the rotor on the axle flange. 6. Install the rear brake caliper mounting bracket. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Refer to Vehicle Lifting. 9. Refill the brake master cylinder reservoir, if needed. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 10. Pump the brake pedal slowly and firmly in order to seat the brake pads. 11. Burnish replaced or refinished rotors. Page 9923 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 9213 Electrical Symbols Part 8 Page 15123 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 12315 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 10866 REMOVAL PROCEDURE 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4. Remove the rear HVAC control-auxiliary from the vehicle. INSTALLATION PROCEDURE Page 8412 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 14846 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 2485 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 14293 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Page 10113 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 1335 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 11674 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15678 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4000 Electrical Symbols Part 4 Page 3718 Water Pump: Service and Repair Water Pump Replacement ^ Tool Required J 41240 Fan Clutch Wrench Removal Procedure 1. Drain the coolant. 2. Remove the fan and shroud. 3. Remove the drive belt. 4. Using the J41240, secure the water pump pulley and remove the water pump pulley bolts. 5. Remove the J41240. 6. Remove the water pump pulley. 7. Loosen and remove the water pump bolts. 8. Remove the water pump. 9. Clean and inspect the water pump. 10. Discard and replace the gasket. Installation Procedure Page 13113 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. Page 9625 Auxiliary Power Outlet: Locations Locations View Locations Lock Cylinder Switch: Locations Locations View Page 10959 Heater Control Valve: Service and Repair COOLANT BYPASS VALVE REPLACEMENT TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181, disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose toward in order to disengage the hose from the heater core. 4. Position the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the vacuum hose from the coolant bypass valve. 8. Remove the coolant bypass valve. 9. Position the clamps at the coolant bypass valve. 10. Remove the heater inlet hoses form the coolant bypass valve. INSTALLATION PROCEDURE Page 15376 Tachometer: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Rearview Mirrors (Outside) - Uncommanded Movement Door Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 93 Disclaimer Page 3002 14. Remove the valve spring retainer and the valve 15. Use the J 38320 and remove the seals. 16. Clean and inspect the cylinder head. Installation Procedure Important: Lubricate the valve stems with clean engine oil before installing. 1. Use the J 33820 to install the valve seals. There is only one size seal. Page 11718 Page 8874 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 150 Nm (110 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 13125 Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (TrailBlazer, Envoy, Bravada) Window Regulator Replacement - Rear Door (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the speaker 4. Loosen the regulator window carrier bolts. 5. Raise and support the window. 6. Disconnect the electrical connector from the regulator motor. 7. Remove the 3 bolts that retain the window regulator assembly to the door. 8. Remove the window regulator assembly from the door. Installation Procedure 1. Install the window regulator assembly to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts that retain the window regulator assembly to the door. Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connector to the regulator motor. 4. Remove the window support and lower the window onto the regulator window carrier. 5. Loosely tighten the regulator window carrier bolts. 6. Operate the window upward to the full up position, ensuring the window remains in the run channels. Tighten the regulator window carrier bolts to 10 N.m (88 lb in). 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 4282 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 16023 Turn Signal/Multifunction Switch C4 Windshield Wiper Washer Switch (Multifunction Switch C3) Page 12674 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 743 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 7641 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14140 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE Page 16006 Conversion - English/Metric Page 11493 9. Remove the seat belt retractor bracket bolt (1) from the bracket and seat back frame. 10. Remove the seat belt retractor bracket from the seat back frame. INSTALLATION PROCEDURE 1. Position the seat belt retractor bracket on the seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Page 4256 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Radiator Hose Replacement- Inlet Radiator Hose: Service and Repair Radiator Hose Replacement- Inlet Radiator Hose Replacement- Inlet (Body Vin Code 3) ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Page 12160 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 14938 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 2458 1. Install the outlet radiator hose clamps to the radiator hose (1). 2. Install the outlet radiator hose (1) to the radiator. 3. Reposition the outlet radiator hose clamp using J38185. 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the outlet radiator hose to the thermostat (1). 7. Reposition the outlet radiator hose using J 38185. 8. Fill the cooling system. Page 6966 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 9733 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 11481 Tighten the screws to 3 Nm (26 lb in). 44. Reposition the seat switch bezel to the side of the seat cushion and install the screws. Tighten Tighten the screws to 3 Nm (26 lb in). 45. If equipped, install the lumbar support knob. 46. If equipped, install the recliner handle and screw. Tighten Tighten the screw to 3 Nm (26 lb in). 47. Connect the side impact air bag electrical connector under the seat. 48. Install the SIR fuse. 49. Turn the ignition switch to the ON position and verify that the SIR light flashes seven times and goes out. 50. For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Page 15144 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 12669 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 15344 Electrical Symbols Part 5 Page 6290 Disclaimer Page 163 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 5468 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 12679 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 7409 6. Find the halfshaft retaining snap ring (3), which is located in the inner race (2). 7. Spread the snap ring ears apart using J 8059 (or equivalent). 8. Pull the CV joint from the halfshaft (4). 9. Discard the old seal. 10. Place a brass drift against the cage (1). 11. Tap gently on the brass drift in order to tilt the cage. 12. Remove the first ball (2) when the cage tilts. 13. Repeat the previous step to remove all of the balls. 14. Pivot the cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 15. Lift out the cage (4) and the inner race. Page 13824 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Valve Lash Adjuster Replacement ^ Tools Required J 36660-A Torque Angle Meter - J 44222 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the exhaust and the intake sprocket bolts. 3. Install the J44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain off of the camshafts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 5. Remove the camshaft cap bolts. 6. Remove the camshaft caps. Page 4073 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 8011 1. Install the mounting bracket to the transfer case control module. 2. Install the electrical connectors to the transfer case control module. 3. Install the transfer case control module assembly to the center support bracket. 4. Install the left hand heat, vent, and air conditioning vent assembly. Page 5285 Various symbols are used in order to describe different service operations. Page 2553 Disclaimer Page 8785 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 2637 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 9064 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 2438 Tighten Tighten the nut to 48 N.m (35 lb ft). 10. Install the sealing washers. 11. Connect the compressor suction/discharge hose to the compressor (4). 12. Install the compressor suction/discharge hose washers. 13. Install the retaining nut (3). Tighten Tighten the nut to 33 N.m (24 lb ft). 14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the components using the J 39400. TrailBlazer EXT and the Envoy XL. TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor suction/discharge hose nut (3). 3. Remove the compressor suction/discharge hose from the compressor (4). 4. Remove the sealing washers. Page 10394 Suspension Strut / Shock Absorber: Specifications Front Shock Absorber Retaining Nut 33 ft. lbs. Shock Module Upper Retaining Nuts 33 ft. lbs. Shock Module Yoke to the Lower Control Arm Retaining Nut 81 ft. lbs. Shock Module Yoke to the Shock Absorber Pinch Bolt 52 ft. lbs. Rear Shock Absorber Lower Mounting Bolt 52 ft. lbs. Shock Absorber Upper Mounting Bolt 59 ft. lbs. Page 4060 Electrical Symbols Part 1 Page 1411 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Service and Repair Service 4WD/AWD Indicator Lamp: Service and Repair Service AWD/4WD Indicator Lamp Illumination of the Lamp indicates a problem with the drive system. There will probably be a Transfer Case Code set to aid in diagnostics. The only way to get the light to go off is to clear Transfer Case codes. This light can NOT be shut off or reset any other way. Transfer Case codes should be read and repaired before clearing them. Refer to Transfer Case. See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Page 4636 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3343 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 14461 1. Install the 3 bolts securing the rear seat cushion latch to the seat pan. Tighten Tighten the rear seat cushion latch release bolts to 10 N.m (88 lb in). 2. Install the small loop (1) onto the rear seat cushion latch (2). 3. Install the strap through the opening in the seat pan. 4. Install the rear-seat cushion cover and the pad. 5. Install the rear seat cushion assembly to the vehicle. Seat Back Release Latch Replacement - Rear No. 1 REMOVAL PROCEDURE Page 3021 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 14377 Seat Cover: Service and Repair Seat Cushion Cover and Pad Replacement - Front REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove the 4 nuts that retain the seat pan to the seat adjuster assembly. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. 4. Release the J strips (1, 3) on each side of the seat cushion. 5. Release the front/rear J strips (2,4). Page 13529 Console Replacement Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the rubber ash tray inserts and rubber mat from the console. 3. Remove the floor shift control knob. 4. Remove the center console shift lever bezel, Oldsmobile only. 5. Remove the console storage compartment. 6. Remove the center console retaining screws. 7. Adjust the parking brake to the full-up, or fully engaged position. 8. Release the 2 forward trim extensions ears attached to the lower IP-Oldsmobile only. 9. Slide the console rearward and raise the rear of the console in order to expose the electrical connectors. 10. Disconnect the electrical connectors as necessary. 11. Adjust the parking brake to approximately the halfway position. 12. Remove the center console from the vehicle. Installation Procedure 1. Position the center console to the vehicle. 2. Adjust the parking brake to the full-up, or fully engaged position. 3. Connect the electrical connectors as necessary. 4. Lower the rear of the console and slide the console forward into position. 5. Ensure that the 2 retaining ears on the front extensions of the console are fully engaged to the lower IP-Oldsmobile only. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the center console retaining screws. Tighten the screws to 2.5 N.m (22 lb in). 7. Install the console storage compartment. 8. Install the center console shift lever bezel. 9. Install the floor shift control knob. 10. Install the rubber ash tray inserts and rubber mat to the console. 11. Remove the bocks from the vehicle. Console Storage Bin Replacement Page 1650 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1293 Fuel Pump And Sender Assembly Page 9240 Generator Page 3425 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-965 Page 4857 Electrical Symbols Part 1 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 5627 Involved are certain 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles built within the VIN breakpoints shown above. Parts Information Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement in SI. 2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement in SI. 3. Replace the fuel sender assembly with the new fuel sender assembly provided in the kit. The kit does not provide a new fuel level sensor. Transfer the fuel level sensor from the old fuel sender assembly onto the new fuel sender assembly. Refer to Fuel Sender Assembly Replacement in SI. 4. Install the fuel tank. Refer to Fuel Tank Replacement in SI. Claim Information For vehicles repaired under the terms of this special coverage, submit a claim with the information shown above. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct this condition are to be submitted to the dealer prior to or by October 31, 2009. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Page 6011 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 14772 Electrical Symbols Part 1 Page 4090 Equivalents - Decimal And Metric Part 1 Page 5227 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 9223 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 9929 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 15698 Center Mounted Brake Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 6242 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 9393 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Diagrams Clockspring Assembly / Spiral Cable: Diagrams Inflatable Restraint Steering Wheel Module Coil C1 Inflatable Restraint Steering Wheel Module Coil C2 Page 15479 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15688 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 5783 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15558 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Service and Repair Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 9726 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 13593 36. Remove the 2 push pins from the rear of the headliner. 37. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 38. Fully recline the bucket seats. 39. With the aid of an assistant, release the interlocking strips (1) that retain the headliner to the roof panel. 40. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 41. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner Coupling Replacement - Antenna Inner and Coupling Replacement - Antenna Outer and install the left inboard sunshade retaining clip (5). 4. Install the right rear push pin (2) 5. Install the left rear push pin (3). 6. Install the assist handles to the roof panel. 7. Connect the electrical connector to the cellular phone antenna. 8. Connect the radio control module electrical connector to the right body side window. 9. Install the coat hooks to the roof panel. 10. Connect the radio antenna module electrical connector to the left body side window. 11. Install the upper rear quarter trim panels. 12. Connect the navigation antenna electrical connector, if equipped. 13. Connect the rain sensor electrical connector, if equipped. 14. Connect the inside rear view mirror electrical connector (6). 15. If the vehicle is NOT equipped with a sunroof, seat the 2 interlocking strips (1). Page 15014 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 1715 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 7734 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 5257 Electrical Symbols Part 5 Page 8665 Page 15324 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 7928 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 6405 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 4303 Equivalents - Decimal And Metric Part 1 Page 11569 Disclaimer Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 1774 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 3496 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Page 119 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 11495 6. Install the seat belt into the retractor bracket by guiding the belt through the slot in the bracket. 7. Install the rear seat back pad and cover. 8. Install the rear seat back seat belt bezel onto the seat belt. 9. Install the seat belt bezel to the seat back. 10. Install the seat back bezel push pins. Page 2636 Fuse Block: Service and Repair REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 15726 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 12247 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 3535 Engine Coolant Temperature (ECT) Sensor Diagrams Engine Oil Level And Temperature Sensor Page 1521 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 6788 Accumulator: Specifications Accumulator Cover to Case Bolt ................................................................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Forward Accumulator Cover to Valve Body Bolt ........................................................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 14802 Equivalents - Decimal And Metric Part 1 Locations Locations View Page 5164 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Interior - Console Power Outlet Cover/Seat Interference Seat Cover: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 11150 Blower Motor Switch: Service and Repair HVAC Systems - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 8928 1. Install the brake rotor to the wheel hub. 2. Install the brake caliper assembly to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the brake caliper mounting bolt. ^ Tighten the brake caliper bracket mounting bolt to 150 Nm (110 ft. lbs.). 4. Install the tire and wheel assembly. 5. Lower the vehicle. Refer to Vehicle Lifting. 6. Fill the brake master cylinder to the proper level. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 7. Pump the brake pedal slowly and firmly in order to seat the brake pads. 8. Burnish the replaced or refinished rotors. Rear Page 12226 Page 14628 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Page 2567 Disclaimer Service and Repair Headlamp Switch: Service and Repair REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 10756 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13684 Locations View Body - Assist Step Skid Pad Warping Auxiliary Step / Running Board: All Technical Service Bulletins Body - Assist Step Skid Pad Warping File In Section: 08 - Body and Accessories Bulletin No.: 02-08-61-002 Date: June, 2002 TECHNICAL Subject: Assist Step Skid Pad Warping (Replace Skid Pad) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Side Step Running Board (RPO BVE) Built Prior to May, 2002 Condition Some customers may comment that the assist step skid pad is warped. Cause The fasteners on the bottom side of the skid pad have interference to the attaching slots in the metal plate of the step assembly. This interference causes the pad to warp between the fasteners when exposed to sun and heat. Correction A new assist step skid pad has been released for service to correct this condition. This new pad has revised fasteners that provide more clearance to the attaching slots in the metal plate. Replace the assist step skid pads using the procedure and part numbers listed below. 1. Remove the assist step skid pad using a door trim panel tool. 2. Install the new assist step skid pad. Ensure all fasteners are fully seated. 3. Repeat the above steps for the opposite side. Parts Information Parts are currently available from GMSPO. Warranty Information Page 5143 Electrical Symbols Part 6 Engine Controls - SES Lamp ON/ DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/ DTC's Set On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) # 04032 - (05/13/2004) 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 -Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the power train control module (PCM) on all affected vehicles as identified above including vehicles in new dealer inventory used inventory and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 4789 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 1783 Electrical Symbols Part 3 Page 12503 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12524 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 15719 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15917 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15568 Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure 1. Open the rear liftgate. 2. Remove the two screws that attach both the left and right tail lamp assemblies and remove the lamps from the body. 3. Inspect the part number on both the left and right tail lamp circuit boards. Chevrolet -- New P/N 16532713 Chevrolet Export -- New P/N Page 10006 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Page 3454 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 3610 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 6100 Electrical Symbols Part 4 Recall 02V121000: Fuel Filter Clip Replacement Fuel Line Coupler: All Technical Service Bulletins Recall 02V121000: Fuel Filter Clip Replacement DEFECT: This is an expansion of an earlier recall (02V-121). On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out the fuel filter onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. REMEDY: Dealers will replace the fuel filter quick connect retainers. The manufacturer has reported that owner notification was expected to begin during September 2002. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 8841 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 2223 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 1321 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14442 Tighten the rear seat support bolts to 35 N.m (26 lb ft). 4. Install the rear seat bracket with the four mounting nuts (2). Tighten the rear seat bracket mounting nuts to 25 N.m (18 lb ft). 5. Install the rear seat bracket trim covers (1). 6. Install the seat in the vehicle. Seat Cushion Pull Strap Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Pull Strap Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). Installation Procedure 1. Install the small loop (1) onto the rear seat cushion latch (2). 2. Install the strap through the opening in the seat pan. 3. Install the rear-seat cushion cover and the pad. Page 7296 Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 10340 Air Line: Service and Repair Air Suspension Air Line Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensors to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D - Height and Full Jounce. 3. Ensure that the air suspension system is Repressurized before removing the air suspension air lines. 4. Disconnect the air line from the air spring. 5. Disconnect the air line from the air compressor. 6. Trim off air line at the electrical harness with a sharp cutting tool. Leave remaining air line in the wiring harness. Installation Procedure 1. Install air line to the air compressor using a new fitting. 2. Install air line to air spring. 3. Attach the air line to outside of the wiring harness using wire ties. 4. Lower vehicle. 5. Install air suspension system fuse. 6. Start vehicle and check for leaks. Page 3953 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 10352 Compressor/Pump: Service and Repair Air Spring Compressor Replacement Removal Procedure Caution: Refer to Sudden Release of Pressure in the Air Suspension System Caution in Service Precautions. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D - Height and Full Jounce. Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the air spring compressor to the frame mounting bolts. 4. Disconnect the air inflator switch electrical connection, air supply lines, and air spring compressor vent hose from the air spring compressor. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 2. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 4746 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 15690 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 2470 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 3482 Disclaimer Page 3157 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 1473 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 7299 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). Page 8402 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 2368 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Page 916 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 10274 4. Install the lower control arm to lower control am, bracket mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. Important: Ensure that the lower control arm is parallel to the lower control arm bracket during the installation and tightening of the lower control arm mounting bolts and nuts. This will ensure correct alignment of the lower control arm bushings. 5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten the nuts to 110 Nm (81 ft. lbs.). 6. Connect the shock module yoke to the lower control arm. 7. Install the shock module yoke lower mounting nut. Important: There is a washer between the stabilizer shaft link and the lower control arm made of herded steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. 8. Install the stabilizer shaft link and washer to the lower control arm. 9. Install the stabilizer shaft link retaining nut. Tighten the nut to 100 Nm (74 ft. lbs.). Page 1199 DISCLAIMER Page 15167 Body - Center Mount Brake Lamp Applique loose Center Mounted Brake Lamp: All Technical Service Bulletins Body - Center Mount Brake Lamp Applique loose Bulletin No.: 01-08-66-007C Date: August 27, 2007 TECHNICAL Subject: Center High-Mount Stop Lamp (CHMSL) Applique Loose (Re-Tape Applique) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to include additional model years and change step 7 in the procedure. Please discard Corporate Bulletin Number 01-08-66-007B (Section 08 - Body and Accessories). Condition Some customers may comment that the CHMSL applique is loose on the liftgate glass. Cause A poor bonding of the double-sided adhesive tape between the CHMSL applique and the liftgate glass may cause this condition. Correction Re-tape the CHSML applique to the liftgate glass using the following service procedure: Open the liftgate glass. Remove the screws that retain the applique to the liftgate glass. Do not damage the applique or the liftgate glass when removing the applique from the liftgate glass. With a flat-bladed tool, carefully remove the applique from the liftgate glass. Remove the CHMSL harness grommet from the roof panel. Disconnect the CHMSL harness connector. Place a clean fender cover on a suitable working surface and place the applique on the fender cover. Remove the old adhesive from the underside of the applique. (For Saab Only Remove the two screws from the CHMSL and remove the CHMSL from the applique. Remove all the ribs from the back side of the applique as seen in illustration above. Clean the applique and the CHMSL with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent to the CHMSL lens as seen in the illustration below and install the two screws and tighten). Tighten Page 4393 Electrical Symbols Part 4 Page 7793 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Page 626 Headlamp Relay: Service and Repair HEADLAMP DRIVER MODULE (HDM) RELAY REPLACEMENT TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the headlamp driver module (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the headlamp driver module (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 13961 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 11697 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 11972 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 6145 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8499 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5986 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 7836 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 12308 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 2603 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 10404 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 4700 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9295 Electrical Symbols Part 5 Page 13269 Trunk / Liftgate Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate trim panel. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the trim panel. Page 14178 3. Partially remove the head restraint retractor assembly from the frame. 4. Remove the release cable by sliding the cable retainer over to the large access hole and removing the cable from the head restraint retractor assembly. 5. Remove the retractor assembly from the seat back frame. INSTALLATION PROCEDURE Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 11744 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 14040 For vehicles repaired under warranty, use the table. Disclaimer Page 4346 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5809 Electrical Symbols Part 2 Page 2759 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 11915 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 7706 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1719 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2623 Fuse Block - Rear C3 Page 5773 Electrical Symbols Part 7 Page 5360 1. If replacing the purge bracket, install the purge valve bracket and the attaching bolt (1). Tighten Tighten the purge valve mounting bracket attaching bolt to 10 N.m (89 lb in). 2. Install purge valve (2) on to the purge valve mounting bracket. 3. Connect the EVAP purge pipe to the EVAP canister purge valve. 4. Connect the engine vacuum pipe to the EVAP canister purge valve. 5. Connect the harness connector (2) to the EVAP canister purge valve (1). 6. Lower the vehicle. Audio System - Poor Radio Reception/Station Drifting Antenna Cable: All Technical Service Bulletins Audio System - Poor Radio Reception/Station Drifting Bulletin No.: 05-08-44-016A Date: March 15, 2006 TECHNICAL Subject: Poor Radio Reception or Radio Will Not Stay On Station (Check Antenna Coax Cable Connection and/or Install Antenna Cable Extension) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2004-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2006 GMC Envoy Denali, Envoy Denali XL 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Attention: Vehicles built after December 21, 2004 were produced with the radio antenna extension cable already installed. Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add models and provide another cause for the condition. Please discard Corporate Bulletin Number 05-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on poor radio reception or that the radio will not hold the station. This occurs on either AM or FM bands. Cause The antenna coax cable connection behind the glove box door may not be fully seated or incorrect radio coax impedance. Correction Inspect the antenna coax cable connection and/or install an antenna extension cable, P/N 15267997, using the following procedure. 1. Remove the right closeout/insulator panel from the IP. 2. Verify that the antenna coax cable connection leads are fully seated. 3. If the leads are fully seated, separate the connection and install an antenna extension cable, P/N 15267997, between the two leads. 4. Install the right closeout/insulator panel to the IP. Parts Information Warranty Information (excluding Saab U.S. Models) Page 5686 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 14777 Electrical Symbols Part 6 Page 14950 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 9004 1. Install EBCM (2) onto BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Page 285 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 1814 Conversion - English/Metric Page 5461 Fuel Injector: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12604 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 3880 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - 1 The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. POWERTRAIN CONTROL MODULE (PCM) - 2 The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 11479 21. Remove the four push-in fasteners that attach the seat back panel to the seat back frame. 22. Remove the seat belt from the upper retractor bracket by sliding it through the slot. 23. Remove the bolt (1) attaching the upper seat belt bracket to the seat frame. 24. Remove the push-in fastener (2) from the retractor. 25. Remove the lower retractor bolt from the retractor. Page 12064 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Automatic Control Control Module HVAC: Locations Automatic Control Locations View - HVAC Systems - Automatic Page 4719 Equivalents - Decimal And Metric Part 1 Page 14398 9. Install the inboard rear seat back hinge cover with three screws. Tighten Tighten the rear seat back hinge cover screws to 2 N.m (18 lb in). 10. Install the seat belt bezel to the rear seal back with the plastic retainers (2) 11. Install the head restraint assembly. Seat Back Cover and Pad Replacement - Rear No. 2 REMOVAL PROCEDURE Page 8503 Page 5102 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 54 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 15720 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Diagram Information and Instructions Cornering Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15473 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 14402 6. Install the seat back cover flap to the pad with the hog rings (2). 7. Install the J-strips (1) across the bottom of the seat back cover. 8. Install the J-strip (1) to the seat adjuster cross bar (2). 9. Install the screws (3) securing the extension panel (1) to the seat back. 10. Install the extension panel hinge trim (2). 11. Install the head restraint assembly. Seat Cushion Cover and Pad Replacement - Front REMOVAL PROCEDURE Page 5016 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 3690 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Engine Controls - SES Lamp ON/DTC P0135 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 12278 For vehicles repaired under warranty, use the table. Disclaimer Page 10095 10. Maintain the pipe wrench on the opposite end of the rack (6). 11. Place a wrench on the flats of the inner tie rod housing (2). 12. Rotate the inner tie rod housing (2) counterclockwise until the inner tie rod separates from the rack (4). 13. Remove old LOCTITE from the threads (1) of the rack (3) and inner tie rod (2). Installation Procedure 1. Slide the shock dampener (4) forward onto the rack (3). Important: Threads must be clean prior to LOCTITE application. Check the LOCTITE (or equivalent) container expiration date. Use only enough LOCTITE to evenly coat threads. 2. Apply LOCTITE 262 (or equivalent) to the inner tie rod threads (2). 3. Attach the inner tie rod (2) onto the rack (3). 4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). Notice: Refer to Fastener Notice in Service Precautions. Important: The pipe wrench must be placed at the valve end of the steering gear (1) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (1). 5. Place a torque wrench and J34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod housing to 100 Nm (74 ft. lbs.). Page 6672 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 1615 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4473 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 5869 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 8840 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8826 Electrical Symbols Part 1 Page 8038 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12926 3.4. Install the remaining seven retainers. 3.5. Install the forward trim panel retaining bolt first. Do not tighten the bolt. 3.6. Install the rearward trim panel retaining bolt second. 3.7. Tighten the two retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (88 lb in). 4. Install the accessory switch panel. Side Front Door Panel TOOLS REQUIRED J 36796 Clip Removal Tool REMOVAL PROCEDURE 1. Remove the accessory switch panel. 2. Remove the 2 trim panel retaining bolts. 3. Use the J 36796 in order to release the 9 trim panel fasteners from the door. 4. Remove the trim panel from the door. 5. Remove the inside door handle bezel. 6. Remove the outside rear view mirror (ORVM) switch, if equipped. INSTALLATION PROCEDURE Page 1375 Turn Signal/Multifunction Switch C2 Turn Signal/Multifunction Switch C3 Page 1512 Electrical Symbols Part 3 Page 12329 Page 4396 Electrical Symbols Part 7 Page 10923 Disclaimer Page 3223 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 13717 Equivalents - Decimal And Metric Part 1 Page 4962 Electrical Symbols Part 1 Page 11853 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 12451 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Specifications Muffler: Specifications Catalytic Converter to Muffler Nuts 33 ft. lbs. Exhaust Muffler Heat Shield Bolts 62 inch lbs. Page 14218 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 10645 AUXILIARY CONSOLE MODE ACTUATOR The auxiliary console mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. Air Distribution MODE ACTUATOR The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5 volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. DEFROST ACTUATOR The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position. FRONT DEFROST When defrost is selected, the A/C compressor is activated. The A/C compressor clutch will engage when ambient temperatures are above 3°C (38°F). The blower motor will be activated, regardless of the coolant temperature. The HVAC control module will override the auxiliary HVAC control module so a high volume of air is delivered to the front defrost vents. The rear window defogger does not affect the HVAC system. Recirculation Operation The HVAC control module controls the air intake through the recirculation actuator. The recirculation switch closes the recirculation door in order to circulate the air within the vehicle. The outside air switch opens the recirculation door in order to route outside air into the vehicle. Regardless of the blower motor switch position, recirculation is available only in the panel and bi-level mode switch positions. Including the OFF position. The mode switch must be placed in either the panel or bi-level position before the blower motor switch is placed in the OFF position. In order to reduce windshield fogging, outside air is circulated when the mode switch is in the defrost or defog positions. If the recirculation switch is pressed into the ON position when the mode switch is in an unavailable mode position, then the recirculation switch LED will flash 3 times. If the HVAC control module detects a fault with the recirc door the HVAC control module will try to drive the actuator for a predetermined amount of time, to outside air, which is the defaulted position for the recirculation actuator. Air Distribution The HVAC control module controls the distribution of air by the use of a defrost actuator and a mode actuator. The modes that may be selected are: ^ Defrost ^ Defog ^ Panel ^ BI-Level ^ Floor The mode and defrost actuators are connected to the mode and defrost doors by a cam type linkage system. Depending on the position of the door, air is directed through the HVAC module and distributed through various ducts leading to the outlets in the dash. If the HVAC control module detects a fault with the mode or defrost doors the HVAC control module will try to drive the actuator for a predetermined amount of time, to defrost, which is the defaulted position for the mode and defrost door actuators. When the mode switch is placed in the defrost or defog positions the A/C is commanded on and the recirculation door is moved to the outside air position to help reduce window fogging. A/C is available in all modes and recirculation is only available in the panel and bi-level modes. Mode Actuator The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5 volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode Page 3806 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, remove the BCM (1) from the rear electrical center. Page 10005 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 11743 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 3300 DISCLAIMER Electrical - No Start/Multiple Systems Inoperative Driver/Vehicle Information Display: Customer Interest Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Page 5095 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 4092 Various symbols are used in order to describe different service operations. Page 4713 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5958 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 13848 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 4674 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 4405 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4103 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Steering - Hissing Noise From Steering Column Steering Shaft: All Technical Service Bulletins Steering - Hissing Noise From Steering Column Bulletin No.: 05-02-35-006A Date: October 04, 2005 TECHNICAL Subject: Hiss/Rush Noise From Steering (STRG) Column Area (Replace Lower Intermediate Shaft) Models: 2004-2005 Buick Rainier Models 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Models Supercede: This bulletin is being revised to correct the Labor Operation Number. The original bulletin incorrectly states to use Labor Operation E7770. The correct Labor Operation is E7700. Please discard Corporate Bulletin Number 05-02-35-006 (Section 02 - Steering). Condition Some customers may comment on a low volume hiss and/or rush noise heard from the steering column area. The noise may change when the steering wheel is rotated in either direction. The noise may be noticeable with the engine ON, vehicle in PARK, HVAC and Radio OFF. Cause The lower steering column intermediate shaft may be internally grounding out, creating a noise path. Diagnosis and Correction To determine if the lower intermediate shaft is allowing noise to travel from the power steering hydraulic system into the vehicle passenger compartment, follow the steps below. 1. Confirm the customer's concern. Note: Page 13715 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Description and Operation Power Door Lock Switch: Description and Operation The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Page 1351 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the electrical connector and remove the stoplamp switch (1). Installation Procedure 1. Install the electrical connector on the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Specifications Pressure Regulating Solenoid: Specifications Pressure Control Solenoid Bracket to Valve Body Bolt .............................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 7470 Page 7227 Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting 2. Support the transmission with a suitable jack. 3. Remove the nuts securing the transmission mount to the transmission support. 4. Remove the transmission support from the vehicle. 5. Remove the transmission mount bolts (1,2). Page 2242 Rain Sensor: Service and Repair WINDSHIELD OUTSIDE MOISTURE SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The rain sensor retaining ring is permanently mounted to the windshield and is not serviceable. Damage to the windshield or the retaining ring will occur if removed. 1. Disconnect the electrical connector from the rain sensor (1). 2. Carefully pull downward on sensor (1) to release it from the retaining ring (2). IMPORTANT: Do not touch the surface of the sensor when it is removed from the glass. 3. Remove the sensor from the vehicle. INSTALLATION PROCEDURE 1. Clean the mounting location on the windshield using a clean lint free cloth with isopropyl alcohol. 2. Install the rain sensor (1) to the windshield. 3. Connect the electrical connector to the rain sensor (1). Page 4339 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5796 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 13956 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4925 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 14459 Seat Latch: Service and Repair Mid-Position Floor Latch Assembly Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the rear center seat belt buckle assembly from the floor latch assembly. 4. Remove the cable (3) from the mid-position floor latch assembly (2). 5. Remove the bolts (1) securing the mid-position floor latch assembly to the seat cushion frame. 6. Remove the mid-position floor latch assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the mid-position floor latch assembly to the seat cushion frame with the bolts (1). Tighten Tighten the rear seat mid-position floor latch assembly bolts to 35 N.m (26 lb ft). 2. Install the cable (3) to the mid-position floor latch assembly (2). 3. Install the rear center seat belt buckle assembly to the floor latch assembly. 4. Install the trim panel to the seat cushion. 5. Install the seat in the vehicle. Page 4560 Electrical Symbols Part 7 Page 10626 Locations View Page 1083 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 12248 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Seat Back Cover and Pad Replacement - Front Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Front REMOVAL PROCEDURE 1. Adjust lumbar to a relaxed position. 2. Remove the front seat assembly from the vehicle. 3. Remove the seat pad trim panel. 4. Remove the head restraint. 5. Remove the screw that retains the seat belt bezel to the top of the seat back. 6. Release the J-strips (1, 4) across the bottom of the seat back cover. 7. Remove the push pins (3) securing the seat cover (2) to the seat frame. 8. Release the J-strips (1, 4) across the bottom of the seat back cover. Page 13599 9. Remove the handle from the roof panel. 10. Partially lower the headliner in order to expose the front handle retaining tab (1). 11. Insert the tip of a flat bladed tool into the front retaining tab (1). 12. With the retaining tab (1) released, pull down on the handle in order to release the roof panel tab (2) from the bezel. 13. Remove the handle from the roof panel. 14. Rotate the bezels in order to release the bezel retaining tabs. 15. Remove the bezels from the headliner. Installation Procedure 1. Position the bezels to the headliner. 2. Rotate the bezels in order to seat the bezel retaining tabs above the headliner. 3. Install the front and rear roof panel tabs into the bezels. Page 14935 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11448 6. Remove the seat belt anchor nut. 7. Remove the screw that attaches the seat belt bezel to the seat back. 8. Remove the seat belt material from the bezel. 9. Release the J-strips (1, 4) across the bottom of the seat back cover. 10. Remove the push pins (3) securing the seat cover (2) to the seat frame. 11. Remove the head restraint. 12. Using a flat-bladed tool, carefully disengage the plastic strips or channels that retain the seat back cover to the side impact airbag module. Page 15305 Electrical Symbols Part 7 Page 390 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 12544 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 10753 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 11499 4. Install the seat belt (1) to the seat frame with the rear seat belt anchor nut (2). Tighten Tighten all rear center seat belt anchor nut to 60 N.m (44 lb ft). 5. Install the inboard rear seat back cushion hinge cover with 3 screws. Tighten Tighten the rear seat back cushion hinge cover screws to 2 N.m (18 lb in). Page 3224 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3948 Electrical Symbols Part 5 Page 4399 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6764 Page 11823 Page 2741 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Hood Latch Replacement Hood Latch: Service and Repair Hood Latch Replacement Hood Latch Replacement Removal Procedure 1. Remove the grille. 2. Using a grease pencil or other suitable marking device, mark the location of the latch on the mounting bracket. 3. Remove the bolts that attach the latch to the mounting bracket. 4. Disconnect the hood latch cable from the latch. 5. Remove the latch from the vehicle. Installation Procedure 1. Connect the hood latch cable to the latch. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 3593 Electrical Symbols Part 5 Locations Locations View Page 8332 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer Ext, Envoy XL) Transfer Case Speed Sensor Replacement - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case front speed sensor electrical connector. 3. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). Page 2765 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 1503 Intake Air Temperature (IAT) Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 14533 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 12328 Page 5283 Equivalents - Decimal And Metric Part 1 Page 8872 8. Remove the brake pad retaining clips from the mounting bracket, inboard brake pad shown. 9. Remove the brake caliper mounting bracket retaining bolts, lower bolt shown. 10. Remove the brake caliper mounting bracket. Page 9817 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 5340 Page 2251 Windshield Washer Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel (IP) accessory trim plate. 2. Disconnect the electrical connector from the wiper washer switch. 3. Release the wiper washer switch locking tabs. 4. Remove the switch from the trim plate. INSTALLATION PROCEDURE 1. Position the switch to the trim plate. 2. Connect the electrical connector to the wiper washer switch. 3. Install the switch to the instrument panel trim plate, ensuring that the locking tabs are properly seated. 4. Install the instrument panel (IP) accessory trim plate. Page 4190 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9285 Disclaimer Locations Locations View - HVAC Systems - Manual Page 3530 5. Using the J 41240 to secure the water pump pulley, install the fan nut to the water pump shaft in a clockwise rotation. ^ Tighten the fan hub nut to 56 Nm (41 ft. lbs.). 6. Install the transmission cooler lines to the engine and clip into the fan shroud. 7. Install the hood latch support. 8. Install the upper inlet radiator hose to the radiator. 9. Reposition the upper inlet radiator hose clamp using J 38185. 10. Install the air intake baffle. Page 11844 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 10966 For vehicles repaired under warranty, use the table. Disclaimer Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 7295 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Page 14475 3. Install the SIR harness (2) to the seat clips (1, 4). 4. Connect the gray lumbar electrical connector (5), if equipped. 5. Connect the black electrical connector (3) to the seat belt buckle. 6. Connect the black electrical connector (6) to the seat back harness. 7. Install the seat belt buckle to the seat with the nut. Tighten Tighten the seat belt buckle nut to 55 N.m (41 lb ft). 8. Install the seat cushion trim panel. 9. Install the front bucket seat assembly to the vehicle. Page 1668 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 5034 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 12202 Locations View Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Drivetrain - Front Drive Axle Squeal/Squeak Seals and Gaskets: Customer Interest Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Specifications Vacuum Brake Booster: Specifications Power brake vacuum booster mounting nut 30 ft.lbs. Vacuum Power Assist 2.4 in Page 11474 Since there are 8 different versions of seat belts used in this field action and an extremely small number of vehicles that will require the retractor replacement (less than 50 worldwide), part numbers are not listed in this bulletin and dealer listings are not broken down by color. Dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when inspection determines that it is necessary to replace a seat belt retractor. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For PC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and PC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 14840 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11724 Page 13156 Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Remove the headlamp housing panel. 3. Remove the hood latch. 4. Remove the bolts that retain the hood latch support to the radiator support. 5. Remove the hood latch support from the vehicle. Installation Procedure 1. Install the hood latch support to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the hood latch support to the radiator support. Tighten the bolts to 20 N.m (15 lb ft). 3. Install the hood latch. 4. Install the headlamp housing panel. 5. Install the radiator air intake baffle. Page 15466 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 11305 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. INSTALLATION PROCEDURE Page 6408 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 15765 Electrical Symbols Part 7 Page 5992 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 4759 Scan Tool Does Not Communicate With Class 2 Device - Steps 10-15 Page 13965 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 9900 ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio to the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting 27. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 28. Locate the 8-way connector with the purple CPA. Separate the connector. Remove the CPA from the female side of the connector. 29. Route the new harness under the carpet from the rear of the console to the 8-way connector. 30. Remove the eight wires from the 8-way in line harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Insert the Gray wire into cavity A. ^ Insert the Tan wire into cavity B. ^ Insert the Dark Green wire into cavity C. ^ Insert the Light Green wire into cavity D. ^ Insert the Yellow wire into cavity E. ^ Insert the Brown wire into cavity F. ^ Insert the Light Blue wire into cavity G. ^ Insert the Dark Blue wire into cavity H. 31. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 32. Cut the wires and terminals from the wires you have removed from the 8-way connector as close to the taped portion of the original wiring harness as possible. 33. Reposition the rear electrical center through the carpet and reposition the carpet. 34. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 35. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 36. Insert the ignition key and turn to the RUN position Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 37. Turn the key OFF. Remove the key. Page 15672 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13030 Page 5912 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 7186 Disclaimer Page 5151 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9208 Electrical Symbols Part 3 Page 12318 Circuit/System Testing Component Testing Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump Mounting Bolts 18 ft. lbs. Page 4013 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Specifications Brake Hose/Line: Specifications Brake Hose to Frame Bolt 18 ft. lbs. Brake Pipe Fittings 18 ft. lbs. Rear Brake Hose to Frame Bolt 18 ft. lbs. Front Brake Hose Bolt 40 ft. lbs. Rear Brake Hose Bolt 40 ft. lbs. Front Brake Lines to BPMV 18 ft. lbs. Rear Brake Line to BPMV 18 ft. lbs. Master Cylinder brake lines to BPMV 18 ft. lbs. Page 10360 Diagrams Cellular Microphone Page 2078 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5152 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Recall - Fuel Filter Fitting Retainer Replacement Technical Service Bulletin # 02016 Date: 020501 Recall - Fuel Filter Fitting Retainer Replacement File In Section: Product Recalls Bulletin No.: 02016 Date: May, 2002 PRODUCT SAFETY RECALL SUBJECT: 02016 - FUEL FILTER FITTING DISCONNECT MODELS: 2002 CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles. Some of these vehicles have a condition where a fuel filter fitting may become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out of the fuel filter onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. Under this condition, the vehicle could be maneuvered to a stop with manual steering efforts, and sufficient power brake assist would be maintained to bring the vehicle to a stop. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. CORRECTION Dealers are to replace the fuel filter quick connect retainers. VEHICLES INVOLVED Involved are certain 2002 Chevrolet TrailBlazers, GMC Envoys, and Oldsmobile Bravadas. Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. Not all vehicles are involved. Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Important: An initial supply of parts required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 6, 2002. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. SERVICE PROCEDURE 1. Open the hood. Page 15519 Equivalents - Decimal And Metric Part 1 Page 10461 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 10739 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 1015 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Specifications Water Pump: Specifications Water Outlet Bolt 89 inch lbs. Water Pump Bolt 89 inch lbs. Page 8446 Paint - Chips Behind Front Wheels/Front of Rear Wheels Paint: Customer Interest Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1498 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. LF Locations Locations View Page 9766 C104 Part 2 C105 Page 12920 1. Install the check link assembly through the door access hole. Ensure that the position arrow is pointing forward. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 check link retaining nuts to the door. Tighten nuts to 7 N.m (62 lb in). 3. Install the rubber dust boot to the check link. 4. Install the 2 bolts that retain the check link to the pillar. Tighten the bolts to 15 N.m (11 lb ft). 5. Install and fully seat the water deflector. 6. Install the door trim panel. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 86 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 13970 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Locations Locations View - HVAC Systems - Manual Page 14389 12. Release the cover from the hook and loop retaining strips on the front of the seat back pad. 13. Remove the 6 push-pins from the seat back. 14. Remove the cover and pad from the seat back. 15. Release the 3 hog-rings from the reinforcement bar. 16. Remove the seat cover from the pad. Page 7405 6. Place the top half of the J 41048 on the bottom half. 7. Check to make sure there are no pinch points on the boot before proceeding. 8. Insert the bolts (2). 9. Tighten the bolts (2) by hand until snug. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the following items: ^ The boot ^ The halfshaft bar ^ The swage clamp Tighten Each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 11. Loosen the bolts. 12. Separate the dies. Important: If deformities exist in the swage clamp, place the swage clamp back into J 41048. Ensure the swage clamp covers the whole swaging area. Re-swage the swage clamp. 13. Check the swage clamp for any "lip" deformities. Important: Assemble the joint with the convolute retainer in the correct position. Assemble the joint to meet the specified dimension to avoid boot damage. 14. Install the convolute retainer over the boot capturing four convolutions. Page 11147 Blower Motor Switch - Front Auxiliary Page 10573 Disclaimer Page 6793 4. Install the J25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the spacer plate support and the spacer plate support retaining bolts. ^ Tighten the spacer plate support retaining bolts to 11 Nm (97 inch lbs.). Page 296 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 11037 Disclaimer Page 6382 For vehicles repaired under warranty, use the table. Disclaimer Air Suspension Sensor - LR AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 5372 Canister Vent Valve: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the harness connector (2) from the evaporative emission (EVAP) canister vent valve. EVAP Vent Valve 3. Disconnect the EVAP vent pipe (3) from the EVAP canister vent valve (1). 4. Disengage the bracket retaining tab (2) and remove the EVAP canister vent valve. INSTALLATION PROCEDURE Page 9588 27. Remove the CPA from the rear audio control connector and remove the eight wires from the designated cavities of the rear audio control in-line harness connector and replace them with the wires from the new harness as listed below. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. Also, this wiring harness has two Dark Blue and two Brown wires. It may be necessary to cut a small portion of the electrical tape wrap to determine which wires are paired. ^ Pair One - Remove wire in cavity B3 and insert the Brown/White wire. - Remove wire in cavity A8 and insert the Brown wire. ^ Pair Two - Remove wire in cavity A9 and insert the Dark Blue wire. - Remove wire in cavity A1 and insert the Black wire. ^ Pair Three - Remove wire in cavity B1 and insert the Brown wire. - Remove wire in cavity B5 and insert the Yellow wire. ^ Pair Four - Remove wire in cavity B6 and insert the Light Blue wire. - Remove wire in cavity B2 and insert the Dark Blue wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires as close to the taped portion of the original harness as possible. 28. Lift the carpet in the left rear door area, and slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 29. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 30. Route the new harness under the carpet from the rear of the console to the 8-way connector. 31. Remove the eight wires from the 8-way inline harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. ^ Remove wire in cavity A and insert the Gray wire. ^ Remove wire in cavity B and insert the Tan wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Light Green wire. ^ Remove wire in cavity E and insert the Yellow wire. ^ Remove wire in cavity F and insert the Brown wire. ^ Remove wire in cavity G and insert the Light Blue wire. ^ Remove wire in cavity H and insert the Dark Blue wire. ^ Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. Page 9550 32. Reposition the rear electrical center through the carpet and reposition the carpet. 33. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 34. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 35. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in order, proceed to the next step. Otherwise, check your work. 36. Turn the key OFF. Remove the key. 37. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 38. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 39. Reinstall the rear electrical center cover. 40. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the attaching screws. 41. Reinstall the knee bolster (TrailBlazer). 42. Reinstall the left side closeout/insulator panel (TrailBlazer). 43. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 44. Reinstall the console to the vehicle and install the retainers. 45. Reinstall the shift boot and handle assembly. 46. Reinstall the console bin and retainers. 47. Reinstall the first lock pillar trim and carpet retainers to both door openings. 48. Position the driver's seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 49. Reinstall the SIR fuse # 18 in the underhood rear electrical center and close the hood. 50. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios Without Rear Audio Controls These vehicles use wiring harness P/N 15164934. 1. Remove the key from the lock cylinder. Page 7853 Transfer Case Actuator: Specifications NVG126-NP4 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) NVG 226-NP8 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) Page 14130 Sun Shade: Service and Repair SUNROOF SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the glass panel. 2. Remove the screws (1) that retain the water trough to the sunroof assembly. 3. Remove the water trough from the sunroof assembly from the top of the vehicle. IMPORTANT: The sunshade must be removed from the top of the vehicle. 4. Slide the sunshade forward. 5. Flex the center of the sunshade (2) upward while simultaneously sliding the panel sideways to release the retaining tabs (3) from the track slot (1). 6. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE Page 4966 Electrical Symbols Part 5 Page 4252 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System ACCIDENT WITH OR WITHOUT INFLATOR MODULE DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. ^ The steering column - Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering. ^ The IP knee bolsters and mounting points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. ^ The IP brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage. ^ The seat belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. ^ The IP cross car beam - Inspect for bending, twisting, buckling, or any other type of damage. ^ The IP mounting points and brackets - Inspect for bending, twisting, buckling, or any other type of damage. ^ The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage. ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving air bag deployment, replace the following components. ^ Inflatable restraint IP module ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint electronic frontal sensor (EFS) (if equipped with dual stage air bags) Perform additional inspections on the following components. ^ Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. ^ Mounting points or mounting hardware for the IP module, steering wheel module, SDM, and EFS sensor (if equipped with dual stage air bags) Inspect for any damage and repair or replace each component as needed. ACCIDENT WITH SIDE AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving side air bag deployment, replace the following components. ^ Inflatable restraint side impact sensors (SIS) (Left/Right), on the side of the impact. ^ Inflatable restraint side impact module (LF/RF), on the side of the impact. ^ Inflatable restraint sensing and diagnostic module (SDM). Perform additional inspections on the following components. ^ Mounting points or mounting hardware for the SIS, and side impact module (LF/RF) on the side of impact - Inspect for any damage and repair or replace each component as needed. ^ Mounting points or mounting hardware for the SDM - Inspect for any damage and repair or replace each component as needed. SENSOR REPLACEMENT GUIDELINES The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 4726 Powertrain Control Module (PCM) C3 Page 15525 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 3. Disconnect the electrical connector from the sensor. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Page 8727 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 1143 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Page 7147 Torque Converter: Specifications Converter Housing to Case Screw ............................................................................................................................................ 65.0-75.0 Nm (48-55 ft. lbs.) Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 5124 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The FTP sensor mounts in the top of the fuel tank-sending unit. The PCM provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the PCM that can vary between 0.1-4.9 volts. As fuel tank pressure increases, FTP sensor voltage decreases (high pressure = low voltage). As fuel tank pressure decreases, FTP voltage increases (low pressure or vacuum = high voltage). Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY Fuel Rail Assembly The fuel rail assembly attaches to the cylinder head. The fuel rail assembly performs the following functions: ^ Positions the fuel injectors in the cylinder head ^ Distributes fuel evenly to the fuel injectors ^ Integrates the fuel pressure regulator with the fuel metering system Locations Locations View Page 11951 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9468 C308 C309 (Long Wheelbase Body,Type VIN 6) Part 1 Page 1315 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 322 1. Install the processor bracket to the rear seat studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the rear seat back stud. Tighten Tighten the nut to 45 N.m (33 lb ft). 3. Position the upper bracket to the processor bracket. 4. Slide the upper bracket outboard until all the retaining tabs are seated to the processor bracket. 5. Install the communication interface module. 6. Install the right rear seat cushion. Page 5049 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 11721 Page 7265 Body/Frame - Roof Rack Wind Noise Roof Rack Frame: Customer Interest Body/Frame - Roof Rack Wind Noise File in Section: 08 - Body and Accessories Bulletin No.: 02-08-67-005 Date: May, 2002 INFORMATION Subject: Proper Position and Installation of Roof Rack Cross Rails to Reduce Wind Noise Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBrazer, TrailBlazer EXT, Envoy, Envoy XL) 2002 Oldsmobile Bravada Some of the above vehicles may exhibit wind noise related to the roof rack. In an effort to reduce wind noise, Engineering has identified a specific position and installation for the roof rack cross rails. ^ Beginning on September 6, 2001 the TrailBlazer, Envoy, and Bravada were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the TrailBlazer EXT and Envoy XL were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the directional arrows were removed from the cross rails on all models to eliminate any confusion as to which direction is correct. It has been found that some dealers are changing the direction of the cross rails thinking they were installed incorrectly. To obtain the optimum position and installation of the roof rack cross rails that produce the least wind noise, use the following procedure: 1. If the cross rails have directional arrows, they should be installed in the reverse direction (arrows toward rear of vehicle). Remove the cross rails and rotate as necessary. 2. If the directional arrows are not present, installation can be verified by checking the location of the cross rail eyelets. When the location of the cross rail eyelets. When installed in the reverse direction, the cross rail eyelets will face the rear of the vehicle. Remove the cross rails and rotate as necessary. 3. Once the specified direction has been established, adjust the position of the cross rails, so that one cross rail is positioned at the rear most end of the vehicle. The other cross rail should then be positioned at approximately midpoint of the rear door glass. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4884 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 3904 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Stud 89 inch lbs. Page 14259 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Seat Recline Motor - Driver/Passenger Locations Locations View Page 1216 Air Temperature Sensor Assembly - Inside Page 3392 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 5748 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9207 Electrical Symbols Part 2 Page 6671 HVAC Systems - Manual Blower Motor Switch: Service and Repair HVAC Systems - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 3319 14. Remove the timing chain tensioner shoe bolt. 15. Remove the timing chain tensioner shoe. 16. Remove the timing chain tensioner guide bolts. 17. Remove the timing chain tensioner guide. 18. Remove the timing chain tensioner bolts. 19. Remove the timing chain tensioner. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Every seventh link of the timing chain is darkened to aid in aligning the timing marks. Page 6924 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 15311 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Fuse Block - Rear (Short Wheelbase) Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 8999 Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions Caution: Refer to Brake Pipe Replacement Caution in Service Precautions. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 inch) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Remove 1/4 inch of the protective coating before flaring the end of the brake pipe. 2. Bend the brake pipe to achieve proper fit. 3. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. 4. Install the brake pipe fasteners to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Important: After tightening the brake pipe fittings to the proper specification, apply a small amount of silicone sealant to the area where the brake pipe meeting the brake pipe fitting. 5. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the BPMV or the wheel jounce hoses to 20 Nm (15 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 30 Nm (22 ft. lbs.). ^ Tighten the brake pipe fittings to the brake hose fitting to 20 Nm (20 ft. lbs.). 6. Bleed the brake hydraulic system. Refer to one of the following procedures: ^ If the brake pipe that was replaced was between the master cylinder and the BPMV, refer to ABS Automated Bleed Procedure. ^ If the brake pipe that was replaced was between the BPMV and the wheel jounce hoses, refer to Hydraulic Brake System Bleeding Page 10715 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Lower Right REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2) INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Page 11446 All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Procedure Important Head the following three steps completely before attempting the procedure. Perform the following inspection procedure on the driver's and front passenger seat belts. 1. Open the driver's door and Buckle The Seat Belt. 2. Using your RIGHT hand, begin SLOWLY pulling the seat belt out of the seat back. When you have pulled out approximately 12 inches, firmly strike the inboard side of the head restraint with your LEFT hand while continuing to slowly pull out the seat belt. ^ If the seat belt locked up and stopped you from pulling the seat belt out in one continuous motion, the locking feature is working as designed and the seat belt does not need to be replaced. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. ^ If the seat belt did not lock up and you were able to pull the seat belt out in one continuous motion, the seat belt retractor requires replacement. Repeat this inspection procedure on the passenger seat belt using your LEFT hand for pulling the seat belt and your RIGHT hand for striking the head restraint. Page 829 1. Install the SDM to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the SDM to the floor panel. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Connect the electrical connectors (2) to the SDM (1). 4. Return the carpet to the fully installed position. 5. Install the console mounting bracket to the floor panel. 6. Install the floor console. 7. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 8280 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 5088 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Recall 02V121000: Fuel Filter Connector Replacement Fuel Line Coupler: Recalls Recall 02V121000: Fuel Filter Connector Replacement DEFECT: On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. REMEDY: Dealers will replace the fuel filter quick connect retainers. The manufacturer has reported that owner notification began May 20, 2002. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 1208 Locations View - HVAC Systems - Automatic Page 11784 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 899 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6187 For vehicles repaired under warranty, use the table. Disclaimer Page 11698 Various symbols are used in order to describe different service operations. Page 11597 1. Position the radio extension cable to the IP support bars as previously noted. 2. Reach through the IP compartment to connect the antenna cable to the radio. 3. Install the radio extension cable attachments (1) to the IP support bars. 4. Connect the antenna cable (2) to the radio extension cable. 5. Install the inflatable restraint module. Page 13136 * Apply the sound deadening materials. * Apply an approved anti-corrosion primer. * Apply the sealers and refinish as necessary. 7. Install all of the related panels and components. Page 4931 INSTALLATION PROCEDURE IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. Page 7629 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 10899 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Page 12255 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 11817 Page 7121 13. Lower the vehicle. 14. Check the vehicle for proper operation. Page 9487 C307 Part 2 Air Deflector Replacement - Front Bumper Fascia Air Dam: Service and Repair Air Deflector Replacement - Front Bumper Fascia Air Deflector Replacement - Front Bumper Fascia Removal Procedure 1. Release the tabs that retain the air deflector to the fascia. 2. Remove the push-pin retaining the air deflector to the fascia. 3. Remove the air deflector from the fascia. Installation Procedure 1. Install the air deflector to the fascia. 2. Install the push-pin that retains the air deflector to the fascia. 3. Install and fully seat the tabs that retain the air deflector to the fascia. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1418 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. HVAC Systems - Manual Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Manual A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 8110 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 9806 C800 Page 5848 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 2269 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 8403 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 5920 6. Remove the ignition coils (1) from the engine. INSTALLATION PROCEDURE IMPORTANT: Make sure that the ignition coil seals are properly seated to the valve cover. 1. Install the ignition coil (1). NOTE: Refer to Fastener Notice in Service Precautions. Page 14519 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Page 7803 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9016 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the brake master cylinder assembly. 2. Drain the brake fluid from the reservoir. Notice: Do not clamp on the master cylinder body. Doing so may damage the master cylinder. 3. Clamp the flange of the master cylinder body in a vise. 4. Remove the retaining pins for the brake master cylinder reservoir. Page 14831 Electrical Symbols Part 8 Page 11937 Page 4351 Various symbols are used in order to describe different service operations. Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 3971 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Paint Identification Precautions Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Page 9063 Page 12297 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 15604 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 10732 Electrical Symbols Part 8 Page 1496 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The FTP sensor mounts in the top of the fuel tank-sending unit. The PCM provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the PCM that can vary between 0.1-4.9 volts. As fuel tank pressure increases, FTP sensor voltage decreases (high pressure = low voltage). As fuel tank pressure decreases, FTP voltage increases (low pressure or vacuum = high voltage). Page 14141 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Page 15350 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 11812 Page 4004 Electrical Symbols Part 8 Electrical Specifications Fuel Injector: Electrical Specifications Resistance Ohms Resistance Ohms ECT between 50 - 90degrees F (10 - 32 degrees C) Ohms 11.0-14.0 Page 9130 Page 12164 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1790 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Specifications Camshaft Bearing: Specifications Camshaft Cap Bolt 106 inch lbs. Page 9451 connector/leads on the body harness by splicing in the service pigtail, P/N 15306403, using the procedure listed below. Passenger Door 1. Inspect the passenger door harness connector (9 wires) and terminals (inline to body harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors sub-section of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (9 wires) and terminals (inline to passenger door harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If there is evidence of corrosion, replace the mating connector/leads on the body harness by splicing in the service pigtail, P/N 88953131, using the procedure listed below. Service Pigtail Procedure 1. Remove the closeout/insulator panel. 2. Remove the door sill plate. 3. Pull back the carpet for access. 4. Remove the driver foot rest pad. 5. Release the harness to body clips. 6. Pull the existing body harness through the door jam and into the body. 7. Cut the existing harness and splice in the service pigtail. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 8. Feed the harness through the body and into the door jam. 9. Install the harness to body clips. 10. Install the driver foot rest pad. 11. Install the carpet in place. 12. Install the door sill plate. 13. Install the closeout/insulator panel. Service and Repair Power Steering Valve: Service and Repair "For information regarding this component please refer to power steering service and repair" Page 1687 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 6249 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. HVAC Systems - Manual Blower Motor Control Processor - Auxiliary (Body Type VIN 6) Page 4398 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 9031 9. Install the park brake cable to the mounting bracket, ensuring the locking tabs are secured. 10. Install the rear brake caliper and mounting bracket assembly. 11. Install the tire and wheel assembly. 12. Lower vehicle. Refer to Vehicle Lifting. 13. Enable the park brake automatic adjuster. Page 11132 Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Page 12149 Electrical Symbols Part 7 Page 2933 Page 10203 The steering wheel puller legs currently recommended in the Service Manual for use with steering wheel puller J 1859-A are incorrect and will not work on these vehicles. The correct steering wheel puller legs that should be used with steering wheel puller J 1859-A are J 36541-A or J 42578. The Steering Wheel Replacement procedure has been updated with the correct steering wheel puller tool usage. Refer to the table for SI Document ID numbers. Disclaimer Electrical - Intermittent Interior Electrical Concerns Hazard Warning Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 1327 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5833 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5834 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1743 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 1170 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Page 13727 Front Passenger Door Module (FPDM) C3 Page 15608 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 13320 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9785 C101 Part 2 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes C104 Part 1 Page 15369 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1416 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15480 Various symbols are used in order to describe different service operations. Page 9486 C306 C307 Part 1 Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EHCU to Bracket 7 ft. lbs. EHCU Bracket Mounting Bolts 18 ft. lbs. Page 7538 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 9323 Various symbols are used in order to describe different service operations. Page 3598 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 11922 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 11906 Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Page 3030 Drive Belt Vibration Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 10056 3. Install the power steering pump pulley (1) flush against the end of the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the radiator air intake baffle. Page 12072 Various symbols are used in order to describe different service operations. Page 1232 Blower Motor Switch: Service and Repair HVAC Systems - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 13669 Disclaimer Page 15492 Electrical Symbols Part 4 Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Part 1 Turn Signal/Multifunction Switch C1 Part 2 Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 8954 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 12074 Garage Door Opener Page 6776 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 23458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 11914 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Air Temperature Sensor Replacement - Upper Right Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Right REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. Page 9457 C104 Part 2 C105 Page 12224 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 4886 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1457 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 741 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 7596 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11934 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 6268 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 1. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 3. Install the motor/encoder electrical connector. 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 5733 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 4869 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 1858 Electrical Symbols Part 7 Page 5575 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5755 Various symbols are used in order to describe different service operations. Page 5589 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Engine Controls - SES Lamp ON/ DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES Lamp ON/ DTC's Set On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) # 04032 - (05/13/2004) 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 -Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the power train control module (PCM) on all affected vehicles as identified above including vehicles in new dealer inventory used inventory and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 11804 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 15213 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 14303 4. Install the side impact module tub to the seat back frame with 2 push pins (1). NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the inflatable side impact module to the seat back frame with 2 screws (1). Tighten Tighten the side impact module screws to 9 N.m (80 lb in). 6. Install the seat belt and retractor assembly. 7. Install the lumbar assembly. 8. Install the front seat back panel. 9. Install the seat back cover and pad. 10. Install the front seat back. 11. Install the seat trim panel. 12. Install the seat assembly to the vehicle. Page 5304 Electrical Symbols Part 3 Page 1202 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil pressure switch. ^ Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 15585 Electrical Symbols Part 1 Page 10264 Control Arm: Specifications Rear Axle Upper Control Arm Mounting Bolts 96 ft. lbs. Service and Repair Coolant Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain cooling system. 2. Use a 1/4 inch drive in order to open and remove the drain cock. 3. Remove the drain cock. Installation Procedure 1. Install the drain cock. Notice: Refer to Fastener Notice in Service Precautions. 2. Using a 1/4 inch drive tighten the drain cock. ^ Tighten the drain cock to 2.0 Nm (18 inch lbs.). 3. Refill cooling system. Page 5269 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12406 Disclaimer Page 15600 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 6704 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 11517 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Position the side impact sensor (2) to the door. 2. Connect the electrical connector (1) to the side impact sensor (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws which retain the side impact sensor to the door. Tighten Tighten the side impact sensor screws to 8 N.m (71 lb in). 4. Fully seat the water deflector to the door. 5. Install the door trim panel. 6. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 9110 1. Remove the plastic cover from the side rail front corner (2) and inspect the attaching bolt (1) for being overtightened. If the bolt is overtightened, it will appear to be partially recessed into the plastic mounting surface. 2. If this condition is found, remove the bolt and install a flat washer (3), P/N 120385 or equivalent, on the attaching bolt. 3. Install the bolt and washer. Tighten Tighten the bolt to 5 N.m (44 lb in). Part number 120385 is a flat washer with an outside diameter of 14 mm (9/16 in), a hole diameter of 6.5 mm (1/4 in), and a thickness of 1.2 mm (3/64 in). If using an equivalent washer, be sure it has adequate corrosion protection. Correction # 2 Position the rear cross bow (1) at the very rear of the side rails as shown. Position the front cross bow (2) in the middle (3) of the second door (4) opening. Page 11820 Page 699 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. Page 3609 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 15124 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 3203 6. Install the crankcase ventilation hose. 7. Install the MAP sensor electrical connector. 8. Install the engine harness bracket. Secure the bracket with the bolt. ^ Tighten the engine harness bracket bolt to 50 Nm (37 ft. lbs.). 9. Install the front differential vent hose to the engine harness bracket clip. 10. Install all harnesses to the original location onto the engine harness bracket. 11. Install the PCM. 12. Install the throttle body. Page 1950 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11939 Page 10083 ^ Cracks ^ Dents ^ Damage to the threads 2. Replace the parts as needed. 3. Lubricate and install the O-rings seals (2) onto the cylinder lines (1). Important: You must install the smaller cylinder line into the valve housing (3) first. 4. Place the smaller cylinder line (2) into the valve housing (3). Important: Hold the smaller cylinder line (2) in place. Do not torque the cylinder line nut (1). 5. Place the other end of the cylinder line at the gear tube end (4). Finger tighten the cylinder line nut (1) on the smaller cylinder line. Important: You must install the larger cylinder line into the valve housing (3) first. 6. Place the larger cylinder line (2) into the valve housing (3). Important: Hold the larger cylinder line (2) in place. Do not torque the cylinder line nut (1). 7. Place the other end of the cylinder line at the gear tube end (4). Finger tighten the cylinder line nut (1) on the larger cylinder line. Page 3152 Equivalents - Decimal And Metric Part 1 Page 7814 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Specifications Camshaft Housing: Specifications Camshaft Cover Bolt 89 inch lbs. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 134 Page 15993 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 4392 Electrical Symbols Part 3 Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft: All Technical Service Bulletins Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 2359 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 11668 Electrical Symbols Part 3 Page 383 Electrical Symbols Part 7 Page 3317 Timing Chain: Service and Repair Timing Chain, Sprockets, and/or Tensioner Replacement ^ Tools Required J 36660-A Torque Angle Meter - J 44221 Camshaft Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the engine front cover. 3. Release the tension on the timing chain by moving the tensioner shoe in. 4. Place the tee into the tensioner to hold the shoe in place. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 12338 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 6.6L (7.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Sensor Replacement Guidelines Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, the SIR sensor must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 12420 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 2899 Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Cap Bolt First Pass 18 ft. lbs. Final Pass 180 degrees Crankshaft Position Sensor Bolt 89 inch lbs. Crankshaft Rear Housing Bolt 89 inch lbs. Crankshaft Main Journal Diameter 2.7567-2.7574 inch Main Journal Taper - Maximum 0.0002 inch Out Of Round - Maximum 0.0002 inch Cylinder Block Main Bearing Bore Diameter 3.0760-3.0766 inch Crankshaft Main Bearing Inside Diameter 2.7579-2.7592 inch Main Bearing Clearance 0.0004-0.0025 inch Crankshaft End Play 0.0044-0.0153 inch Page 12513 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Interior - Power Memory Seat Inoperative Power Seat Control Module: All Technical Service Bulletins Interior - Power Memory Seat Inoperative Bulletin No.: 01-08-50-011A Date: October 24, 2003 TECHNICAL Subject: Memory Power Seat Inoperative (Replace Memory Seat Module with New Design Module) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22180054 or June 19, 2001 Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 01-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the memory seats or heated seats are inoperative. Cause A logic lock-up of the memory seat module may cause this condition. Correction Important: This repair is not to be performed on vehicles without memory/heated seats. In the event a vehicle without memory/heated seats has an inoperative power seat, use published Service Information for diagnosis. Diagnosis If the seat is currently inoperable, perform the following diagnosis in order to determine if this correction is the correct repair. 1. Connect the Tech 2 to the vehicle. 2. When the main menu is displayed on the Tech 2, verify the software version that is installed in the Tech 2. If it is not software version 21.007 or later which was broadcast to dealerships on August 20, 2001, or CD received August 27, 2001, update the Tech 2. 3. Select Diagnostics. Press Enter. 4. Select model year 2002. Press Enter. 5. Select LD TRK, MPV, Incomplete. Press Enter. 6. Select Body. Press Enter. 7. Select LD Truck line "S" or "T". Press Enter. 8. Select Body Type. Press Enter. 9. Select Air Conditioning Type. Press Enter. 10. Select Driver Seat Module. Press Enter. 11. Select Data Display. Press Enter. 12. Select Input/Output. Press Enter. Page 4144 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10594 Disclaimer Page 3811 INSTALLATION PROCEDURE IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. Page 9969 12. Remove the lower ball joint retaining nut. 13. Remove the steering knuckle from the lower control arm using J43631. 14. Remove the steering knuckle from the vehicle. Installation Procedure 1. Install the steering knuckle to the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower ball joint retaining nut. Tighten the lower ball joint retaining nut to 110 Nm (81 ft. lbs.). Page 1957 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5263 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 7471 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The Propeller Shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A one piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. A/T - Oil Cooler Flushing/Flow Check Procedures Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 2649 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 9771 Multiple Junction Connector: Diagrams C300 - C316 C301 C301 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 5736 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 8989 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Page 3936 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 9646 Fuse Block - Rear C3 Page 6197 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 10086 6. Remove the lower intermediate shaft retaining bolt from the power steering gear. 7. Disconnect the lower intermediate shaft from tile power steering gear. 8. Remove the steering gear crossmember. 9. Remove the power steering hose assembly to the power steering gear retaining bolt. 10. Remove the power steering hose assembly from the power steering gear. 11. Support the power steering gear. 12. Remove the power steering gear mounting bolts. 13. Remove the power steering gear from the vehicle. Page 3860 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 14474 8. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 9. Remove the seat back. INSTALLATION PROCEDURE 1. Install the seat back. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). Page 5455 Electrical Symbols Part 3 Page 6266 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 7. Install the motor/encoder to the transfer case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 8. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 9. Connect the motor/encoder electrical connector (1). 10. Install the fuel tank shield, if equipped. 11. Lower the vehicle. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5683 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 6698 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 5292 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 8430 Page 11819 Page 10008 9. Remove the servo cover retaining ring. 10. Remove the J 29714-A. 11. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 12. Remove the 2-4 servo from the transmission. 13. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure ^ Tools Required J 29714-A Servo Cover Depressor Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 11818 Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 1869 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 11676 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5235 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 9299 Starter Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5218 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 10916 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 9544 WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 40. Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. 41. Reposition the rear electrical center through the carpet and reposition the carpet. 42. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 43. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 44. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 45. Turn the key OFF. Remove the key. 46. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 47. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 48. Reinstall the rear electrical center cover. 49. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 50. Reinstall the knee bolster (TrailBlazer). 51. Reinstall the closeout/insulator panel (TrailBlazer). 52. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 53. Reinstall the console to the vehicle and install the retainers. 54. Reinstall the shift boot and handle assembly. 55. Reinstall the console bin and retainers. 56. Reinstall the first lock pillar trim and carpet retainers to both door openings. 57. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). Page 8040 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Page 14161 1. Position the sunshade to the vehicle from the top of the vehicle. 2. Install the retaining tabs on one side of the sunshade into the track slot of the sunroof. 3. Flex the center of the sunshade (2) upwards while simultaneously inserting the retaining tabs (3) into the track slot (1). 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. 5. Install the water trough to the sunroof from the top of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the screws that retain the water trough to the sunroof. Tighten Tighten the screws to 1 N.m (9 lb in). 7. Install the glass panel. Child Restraint Precautions Child Seat Tether Attachment: Service and Repair Child Restraint Precautions CAUTION: A child in a rear-facing child restraint can be seriously injured if the right-front passengers air bag inflates. This is because the back of a rear-facing child restraint would be very close to the inflating air bag. NEVER use a rear-facing child restraint in this vehicle. If a forward-facing child restraint is suitable for your child, ALWAYS move the front passenger seat as far back as it will go and then install the child restraint. Be sure the child restraint position does not conflict with any additional requirements provided by the manufacture. For more information, refer to the instruction that came with the child restraint. Page 3321 4. Install the cylinder head access hole plugs. ^ Tighten the cylinder head access hole plugs to 5 Nm (44 inch lbs.). 5. Install the J44221 with the camshaft flats up and the number 1 cylinder at top dead center. 6. Install the crankshaft sprocket (1). 7. Install the intake camshaft sprocket into the timing chain. 8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1). 9. Feed the timing chain down through the opening in the head. 10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing mark on to the crankshaft sprocket. Important: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. 11. Install the intake camshaft sprocket onto the intake camshaft. 12. Install the intake camshaft sprocket washer and bolt. Page 1651 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 5003 Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM mounting studs (1) to the intake manifold, if necessary. Tighten Tighten the studs to 6 N.m (53 lb in). Install the PCM (2) to the intake manifold. 2. Install the PCM mounting nuts and bolts (3). Tighten Tighten the nuts and bolts to 10 N.m (89 lb in). 3. Install the PCM harness connectors (3) to the PCM (2). 4. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 5. If a new PCM is being installed, the PCM must be programmed. See: Testing and Inspection/Programming and Relearning Page 3696 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 15323 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 15683 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 13951 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15096 Odometer: Description and Operation The base IPC contains a season odometer and a trip odometer. The uplevel IPC contains a season odometer and two trip odometers. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. The odometer displays either miles or kilometers as requested by the activation of the Personalization button on the steering wheel controls. The odometer is capable of displaying values from 0 to 999,999 MI or KM. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. Trip Odometers The DIC can display Trip A or Trip B odometers. The trip odometers are capable of displaying values from 0 to 9999.9 MI or KM. When the maximum value is reached, the trip odometer will roll over to 0.0. Page 9322 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 737 Electrical Symbols Part 5 Page 15566 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by November 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement~ they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Note: Page 14399 1. Remove the head restraint assembly. 2. Remove the extension panel hinge trim (2). 3. Remover the screws (3) securing the extension panel (1) to the seat back. 4. Remove the J-strip (1) from the seat adjuster cross bar (2). 5. Unhook the J-strip (1) from the bottom of the seat back cover. 6. Remove the hog rings (2) from the seat back cover flaps. Page 1791 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 13063 3. Install the rubber dust boot to the check link. 4. Install the 2 bolts that retain the check link to the pillar. Tighten Tighten the bolts to 15 N.m (11 lb ft). 5. Install and fully seat the water deflector. 6. Install the door trim panel. Page 9325 Starter Motor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the left tire. 3. Working in the left fender area, remove the battery positive lead from the solenoid (1). 4. Remove the starter mount bolt and nut (1,2). 5. Remove the starter motor. INSTALLATION PROCEDURE Page 5476 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5674 Electrical Symbols Part 4 Page 12961 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Weatherstrip Replacement - Front Door Opening Removal Procedure 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Page 15906 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 15761 Electrical Symbols Part 3 Audio/A/C - Settings Change While Driving Body Control Module: All Technical Service Bulletins Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger REMOVAL PROCEDURE Page 5886 Various symbols are used in order to describe different service operations. Page 258 Page 10933 8. Remove the evaporator core (3) from the HVAC module-auxiliary (1). 9. Carefully remove the foam insulator (2) from around the evaporator core-auxiliary (3). INSTALLATION PROCEDURE 1. Transfer the foam insulator (2) to the replacement evaporator core-auxiliary (3). 2. Transfer the thermal expansion valve-auxiliary to the replacement evaporator core-auxiliary. Install the evaporator core-auxiliary (3) to the rear HVAC module-auxiliary (1). Page 3960 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4705 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 977 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 11839 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 5637 1. Place the new fuel feed (1), fuel return (2), or EVAP pipe with the remaining pipes in the fuel bundle. 2. Install the fuel bundle clips as noted during disassembly. 3. Position the fuel pipe bundle along the engine and transmission. 4. Connect the chassis fuel feed pipe (3) to the fuel filter. 5. Connect the engine chassis fuel return pipe to the fuel tank fuel return pipe. 6. Connect the chassis EVAP purge pipe (2) to the EVAP canister (1). Page 1767 Various symbols are used in order to describe different service operations. Page 7372 For vehicles repaired under warranty, use the table. Disclaimer Page 55 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 11455 Suspension - Boom/Rumble Heard at Highway Speeds Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Boom/Rumble Heard at Highway Speeds Bulletin No.: 02-03-09-002C Date: December 06, 2004 TECHNICAL Subject: Intermittent Boom, Rumbling Noise and/or Disturbance Heard in Passenger Compartment While Driving at Highway Speeds (Replace Rear Coil Springs) Models: 2002-2005 Chevrolet TrailBlazer 2002-2005 GMC Envoy with Rear Coil Springs 2003-2004 Oldsmobile Bravada with Rear Coil Springs Built Prior to August 23, 2004 (Refer to Parts Information table below for applicable RPO Code usage) Attention: Do not perform this bulletin for vehicles built after 8/23/04. Supercede: This bulletin is being revised to add the breakpoint of 8/23/2004 for 2005 model year production with an updated spring material. Please discard Corporate Bulletin Number 02-03-09-002B (Section 03 - Suspension). Condition Some customers may comment on an intermittent booming, rumbling noise and/or disturbance heard in the passenger compartment while driving the vehicle at highway speeds. This condition occurs while driving at steady speeds between 1550-1700 engine RPM in 4th gear (NOT during acceleration). This equates to 64-80 km/h (48-50 mph) for vehicles with a 4.10 axle ratio (RPO GT5), 83-86 km/h (52-54 mph) with a 3.73 axle ratio (RPO GT4) and 93-96 km/h (58-60 mph) with a 3.42 axle ratio (RPO GU6). Cause The noise/disturbance occurs when the torque converter momentarily goes to a full lock-up state, resulting in zero slip of the torque converter. When the torque converter returns to normal ECCC mode with 30 RPM of slip, the noise will go away. The disturbance generated by the zero slip condition is amplified and transferred into the passenger compartment by the rear coil springs. Correction Replace the rear coil springs using the following service procedure. Note: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. 2. Support the front frame rail of the vehicle with a suitable adjustable jack stand. 3. Support the rear axle with a suitable adjustable jackstand. 4. Remove the two shock absorber lower mounting bolts. 5. Lower the rear axle enough to remove the tension on the rear coil springs. 6. Remove the rear coil springs. Important: ^ It is critical that the correct coil springs are installed in the correct location. Page 10118 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 10849 HVAC Control Module C2 Page 4147 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 6234 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 5700 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9792 C304 Part 1 Page 13719 Various symbols are used in order to describe different service operations. Page 9222 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14742 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 10331 Stabilizer Link: Specifications Stabilizer Shaft Link Retaining Nuts Front 74 ft. lbs. Rear 74 ft. lbs. Page 287 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 11127 Locations View - HVAC Systems - Automatic Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1970 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 8911 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. AWD/4WD System - Delayed Front Wheel Engagement Control Module: Customer Interest AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 1637 Electrical Symbols Part 1 Page 12908 12. Install and hand tighten the two remaining bolts. Notice: Refer to Fastener Notice in Service Precautions. 13. Align the hinge to the original location. Tighten the bolts to 25 N.m (18 lb ft). 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). 16. Refinish as necessary. 17. Install and align all of the related panels and components. Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 3872 Equivalents - Decimal And Metric Part 1 Specifications Fill Plug: Specifications Front Drive Axle Plug, Drain and Fill .............................................................................................................................. ................................................ 32 Nm (24 ft. lbs.) Rear Drive Axle Fill Plug ................................................................................................................................................ ................................................ 33 Nm (24 ft. lbs.) Page 5007 Engine Control Module: Service and Repair Service Programming System (SPS) SERVICE PROGRAMMING SYSTEM (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: The Vehicle Identification Number (VIN) - The crankshaft variation learned position - The software/calibrations identification numbers - The control module security information - Flash Read Only Memory - Flash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. SERVICE PROGRAMMING METHODS The 4 methods of programming a control module and the proper tools for each method are as follows: Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle - Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. - Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle - Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle. BEFORE PROGRAMMING B CONTROL MODULE IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. - General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. - Heating, Ventilation, And Air Conditioning (HVAC) systems - Engine Cooling fans, etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. - All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Page 5123 Fuel Tank Pressure (FTP) Sensor Page 8607 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Diagrams Trailer Connector: Diagrams Trailer Connector Part 2 Trailer Connector Part 1 Specifications Pressure Regulating Solenoid: Specifications Pressure Control Solenoid Bracket to Valve Body Bolt .............................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 14420 1. Position the bracket assembly on the seat cushion. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts securing the bracket assembly to the seat cushion. Tighten Tighten the rear seat cushion bracket bolts to 25 N.m (18 lb ft). 3. Install the rear seat cushion assembly in the vehicle. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE Page 9236 Equivalents - Decimal And Metric Part 1 Page 4089 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 5472 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Fuse Block - Rear (Short Wheelbase) Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 4620 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 11116 Control Module HVAC: Diagrams HVAC Systems - Automatic Blower Motor Control Module Blower Motor Control Processor - Auxiliary Page 12478 For vehicles repaired under warranty use, the table. Disclaimer Page 7404 1. Position the new swage clamp onto the neck of the boot. Do not swage. 2. Slide the new small swage clamp (2) and the boot (1) to the proper position (3) on the halfshaft bar. 3. Position the neck of the boot in the boot groove on the halfshaft bar. 4. In order to swage the swage clamp, position the inboard end (1) of the halfshaft assembly in J41048. 5. Align the swage clamp (2) within J41048. Page 13366 License Plate Bracket: Removal and Replacement License Plate Pocket Replacement Removal Procedure 1. Remove the license pocket lamps. 2. Remove the liftgate trim panel. 3. Disconnect the bellcrank rod from the outside door release handle. 4. Remove the screws that retain the license pocket to the liftgate. 5. Remove the license pocket from the liftgate. Installation Procedure 1. Install the panel to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the panel to the liftgate, starting with the bottom center screw first. Tighten the screws to 5 N.m (44 lb in). Page 1385 Accelerator Pedal Position (APP) Sensor Page 4134 Electrical Symbols Part 5 Page 7241 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 9618 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 3551 Heater Control Valve: Description and Operation HVAC Systems - Automatic COOLANT BYPASS VALVE The coolant bypass valve controls coolant flow to the auxiliary heater core. Integral to the coolant bypass valve is an electric solenoid that controls vacuum flow to open and close the valve. When the HVAC control module applies 12 volts to the integral solenoid, the solenoid applies vacuum to a diaphragm that closes the water valve. This action restricts coolant flow to the auxiliary heater core. The coolant bypass valve is a normally open valve. If there is a concern with control of the valve or with its vacuum source the valve will still be able to supply heated coolant to the auxiliary heater core. Page 5394 Fuel Pressure: Testing and Inspection SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Fuel System Diagnosis - Steps 1-3 Specifications Spare Tire: Specifications Spare Wheel Hoist Assembly Mounting Bolts 37 ft. lbs. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 5413 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 6303 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 1364 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 4347 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 9464 C304 Part 2 C305 Page 4794 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15783 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 13112 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Inner REMOVAL PROCEDURE 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 4600 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt 89 inch lbs. Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 14832 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12648 Locations View Page 8382 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13118 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. Installation Procedure 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure Page 9347 Locations View Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 6787 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Automatic Control Control Module HVAC: Locations Automatic Control Locations View - HVAC Systems - Automatic Page 15895 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15135 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 11042 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 43600 ACR 2000 Air Conditioning Service Center ^ J 45037 A/C Oil Injector CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (fart) for the correct amount. Page 5110 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 12272 For vehicles repaired under warranty use, the table. Disclaimer Page 7216 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Page 5788 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 10989 Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Install the coolant recovery tank. 6. Install the washer solvent container. 7. Install the nuts (1,5) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the components using the J 39400. TrailBlazer EXT and the Envoy XL. EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Loosen the evaporator tube (5) from the evaporator. 3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping. 4. Remove the evaporator tube nut from the condenser. 5. Remove the nuts (1,2) retaining the evaporator tube to the tender. 6. Remove the washer solvent container. 7. Remove the coolant recovery tank. 8. Remove the evaporator tube using J 26549-E. 9. Remove the O-ring seal and discard. INSTALLATION PROCEDURE Page 7226 Transmission Mount: Specifications Trans Mount to Transmission Bolt ........................................................................................................................................................... 25 Nm (18 ft. lbs.) Page 3674 Electrical Symbols Part 3 Page 5742 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 3641 1. Install the outlet radiator hose clamps to the radiator hose (1). 2. Install the outlet radiator hose (1) to the radiator. 3. Reposition the outlet radiator hose clamp using J38185. 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the outlet radiator hose to the thermostat (1). 7. Reposition the outlet radiator hose using J 38185. 8. Fill the cooling system. Page 11056 Balancing Procedure Important: The refrigerant oil in the A/C system must be balanced during compressor replacement. 1. The replacement compressor is shipped with 240 ml (8.0 oz) of refrigerant oil. 2. Before installing the compressor, the refrigerant oil will have to be partially drained. 2.1. Refer to the amount of refrigerant oil recorded during the compressor removal. 2.2. Subtract the amount recorded from the total system capacity. Refer to Refrigerant System Capacities. The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor. 3. Drain the calculated amount of refrigerant from the replacement compressor. Disclaimer Page 1963 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 8506 5. Remove the motor/encoder assembly. Important: When replacing the encoder rotary position sensor follow these additional steps. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder gasket. 6. Position the motor on a work bench. 7. Release the 4 tabs that retain the motor/encoder gasket and remove the gasket (1). 8. Remove the snap ring and washer retaining the motor/encoder rotary position sensor. Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed. 9. Lift the motor/encoder rotary position sensor (2) from the motor shaft. 10. Disconnect the rotary position sensor (2) from the wiring harness. Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed. Installation Procedure Important: Provided the rotary position sensor was removed, follow steps to install the sensor, otherwise proceed to installing the motor/encoder to the transfer case. 1. Connect the wiring harness to the rotary position sensor. 2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed. Page 453 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Page 15404 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 2852 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 1526 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 5222 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 4723 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Page 1648 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 958 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 3214 Electrical Symbols Part 3 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 2925 5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100). 6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117). 7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401(1). Recall 02V121000: Fuel Filter Clip Replacement Fuel Line Coupler: Recalls Recall 02V121000: Fuel Filter Clip Replacement DEFECT: This is an expansion of an earlier recall (02V-121). On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out the fuel filter onto the ground. If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire. REMEDY: Dealers will replace the fuel filter quick connect retainers. The manufacturer has reported that owner notification was expected to begin during September 2002. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 2469 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 15316 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Memory Seat Module - Driver Power Seat Control Module: Diagrams Memory Seat Module - Driver Memory Seat Module - Driver C1 Page 5800 Conversion - English/Metric Page 10521 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 13996 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Service and Repair Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 11713 Page 2927 11. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100). Cylinder Sleeve Trimming EN 45680-865 Debris Collector (3) EN 45680-411 Trim Tool Assembly (2) Air Control Valve (1 Part of EN 45680-411) Drill Motor with 1/2 inch chuck, 11/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction Trim Tool Cutter Note: Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot. The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN-45680-499) was sent in November, 2004 to affected Chevrolet and GMC dealers. The new pilot is white in color, and should be installed on EN-45680-411 Trim Tool Assembly. Buick and HUMMER dealers were sent EN-45680-400 Cylinder Liner Replacer kit with the correct pilot already installed. Inspect EN-45680-411 to ensure the correct white pilot is installed. The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Trim Tool Preloader (1) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Transfer Case Motor/Encoder Replacement (Trailblazer, Envoy) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the 2HI position. 1. Raise the vehicle. 2. Remove the fuel tank shield, if equipped. 3. Disconnect the motor/encoder electrical connector (1). 4. Remove the motor/encoder mounting bolts. Page 4569 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 11427 Tighten the screws to 3 Nm (26 lb in). 44. Reposition the seat switch bezel to the side of the seat cushion and install the screws. Tighten Tighten the screws to 3 Nm (26 lb in). 45. If equipped, install the lumbar support knob. 46. If equipped, install the recliner handle and screw. Tighten Tighten the screw to 3 Nm (26 lb in). 47. Connect the side impact air bag electrical connector under the seat. 48. Install the SIR fuse. 49. Turn the ignition switch to the ON position and verify that the SIR light flashes seven times and goes out. 50. For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Page 10885 Locations View - HVAC Systems - Manual Page 826 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 4715 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10987 6. Install the compressor suction hose to the stud on the engine. 7. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install the compressor suction hose to the engine lift bracket. 9. Install the bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). 10. Connect the compressor suction hose (1) to the accumulator. 11. Install the compressor suction hose nut to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 12. Install the sealing washers. 13. Connect the compressor suction/discharge hose to the compressor (4). 14. Install the compressor suction/discharge hose washers. 15. Install the retaining nut (3). Tighten Tighten the nut to 33 N.m (24 lb ft). 16. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 17. Leak test the fittings of the components using the J 39400. Page 8558 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 9717 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Latch Replacement - Lift Gate Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the outside handle rod from the bellcrank. 4. Disconnect the bellcrank rod from the latch/lock assembly. 5. Remove the screws that retain the bellcrank to the latch/lock. 6. Remove the bellcrank from the latch/lock. 7. Disconnect the electrical connector from the latch assembly. 8. Disconnect the lock cylinder bellcrank rod (1) from the latch assembly. 9. Remove the screws that retain the latch/lock assembly to the liftgate. 10. Remove the latch/lock assembly from the liftgate. Installation Procedure Page 12870 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 9660 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 12896 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. INSTALLATION PROCEDURE 1. Position the service hinge (1) within the scribe marks (2) on the hinge pillar (3). 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3 mm (1/8 in.) pilot hole at each marked location (1). Page 304 Labor Time Information Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12284 Disclaimer Page 6394 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8281 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 5208 Electrical Symbols Part 1 Specifications Thermostat Housing: Specifications Thermostat Housing bolt 89 inch lbs. Diagrams Engine Oil Level And Temperature Sensor Page 9227 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 11852 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 1794 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9830 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Page 2197 Electrical Symbols Part 6 Page 3507 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 5812 Electrical Symbols Part 5 Page 3523 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 15422 Equivalents - Decimal And Metric Part 1 Page 10604 Disclaimer Page 5441 CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 6. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Close the bleed valve on the fuel pressure gage. 9. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel tank shield if applicable. Page 4714 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 8451 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 10910 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Page 1855 Electrical Symbols Part 4 Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 268 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 4164 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) 1 Heated Oxygen Sensor (HO2S) 2 Page 9013 Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 866 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 9791 C301 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Diagram Information and Instructions Daytime Running Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Service and Repair Video Cassette Player / Recorder: Service and Repair VIDEO PLAYER BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the video display assembly. 2. Remove the two rear overhead console carrier screws (1). 3. Remove the front bracket retaining bolts. Page 3231 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Fuel Filler Neck: Technical Service Bulletins Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Bulletin No.: 05-06-04-014A Date: March 21, 2005 INFORMATION Subject: Diagnostic Aids for Diagnostic Trouble Codes P0440, P0455 and/or P0442 - Evaporative Emission (EVAP) System Leak Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada with 83 Liter (22 Gallon) or 96 Liter (25 Gallon) Fuel Tanks Supercede: This bulletin is being revised to remove the 2005 model year. Please discard Corporate Bulletin Number 05-06-04-014 (Section 06 - Engine/Propulsion System). This bulletin is being published to aid technicians in the diagnosis of DTCs P0440, P0455 and/or P0442. It is possible that a fracture as small as 0.508 mm (0.020 in) may be found in the fuel tank filler neck, causing a DTC P0440, P0455 and/or P0442 to set. Due to the location above the liquid fuel level, this small fracture will not cause a visible fluid leak. The technician should pay particular attention to the fuel tank filler neck area while performing the smoke test outlined in SI. Refer to the appropriate diagnostic information for P0440, P0455 and/or P0442 in SI. When performing the smoke test outlined in SI, it may be necessary for the technician to manipulate the fuel tank filler neck in order to see smoke escaping from this minute fracture. Disclaimer Page 13420 Structural Brace: Service and Repair Frame Brace Replacement (Trailblazer, Envoy, Bravada) Frame Brace Replacement (Trailblazer, Envoy, Bravada) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the 2 mounting bolts from the frame brace. 3. Remove the frame brace from the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the frame brace to the frame using the 2 mounting bolts. Tighten the bolts to 50 N.m (37 lb ft). 2. Lower the vehicle. Page 12535 Locations Locations View Page 3338 Important: The engine front cover must be installed within 10 minutes from when the sealer was applied. 2. Apply a 3 mm (0.12 inch) bead of sealer GM P/N 12378521 to the trace grooves on back side of the engine front cover (1). 3. Also apply sealant on the inside three bolt hole bosses on the cover. 4. Align the oil pump to the crankshaft sprocket splines. 5. Install the front cover. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the front cover bolts, tightening the center bolt last (1). ^ Tighten the front cover bolts to 10 Nm (89 inch lbs.). 7. Remove the J44219. 8. Raise the vehicle. Refer to Vehicle Lifting. 9. Install the oil pan. 10. Lower the vehicle. 11. Install the power steering pump. 12. Install the crankshaft balancer. 13. Install the water pump. 14. Install the drivebelt. 15. Install the cooling fan and shroud. 16. Fill the engine with coolant. Oil Viscosity Engine Oil: Description and Operation Oil Viscosity ENGINE OIL VISCOSITY, UNITED STATES AND CANADA NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. SAE 5W-30 is the only viscosity grade recommended for your vehicle. Use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If the temperature range is-18°F( 0°C) or above SAE 10W-30 oil which has the API Starbust symbol is acceptable if SAE 5W 30 oils is not available. Areas where the temperature falls below -29°F (-20°C), either an SAE 5W-30 synthetic oil or and SAE 0W-30 oil is recommended. Both will provide easier cold starting and better protection for the engine at extremely low temperatures. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. SAE 5W-30 is the recommended engine oil viscosity. Engine oil viscosity thickness has an effect on the fuel economy and the cold-weather operation engine starting and oil flow. Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. When the temperature is consistently above -18°C (0°F), 10W-30 may be used. SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any GMC vehicle at any time. ENGINE OIL QUALITY AND VISCOSITY (OTHER THAN THE UNITED STATES AND CANADA) NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. Page 4006 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6720 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 12507 Page 4875 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13309 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5571 Electrical Symbols Part 5 Page 1268 Low Pressure Sensor / Switch: Locations Locations View - HVAC Systems - Manual Page 15795 Daytime Running Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 13284 Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Liftgate Lock Striker Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Using a grease pencil, mark the position of the liftgate striker to the body. 3. Remove the bolts that retain the liftgate striker to the body. 4. Remove the striker from the body. Installation Procedure 1. Install the striker to the body and position as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the striker to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Adjust the striker, if necessary. 4. Close the liftgate. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 3349 Fuel System Diagnosis - Steps 4-11 Page 1608 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 812 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 11366 Seat Belt: Service and Repair Lower Anchor Assembly Replacement - Rear No.1 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (2) securing the lower anchor (1) to the seat cushion frame. 4. Remove the lower anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the rear seat lower anchor to the seat cushion frame with the bolt (2). Tighten Tighten the rear seat lower anchor bolt to 35 N.m (26 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 147 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 4293 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 2752 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 5684 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 12240 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 1630 2. Install the heated oxygen sensor (2). Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 11422 3. If both the driver and passenger front safety belts lock when performing the inspection, no further action is required. If any of the seat belts did not lock up, refer to the Seat Belt Retractor Replacement Procedure, and replace the applicable retractor. Seat Belt Retractor Replacement Important The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information. Important For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Important Do not remove the seat from the vehicle when performing the following procedure. 1. Remove the SIR fuse. 2. Disconnect the side impact air bag electrical connector located under the seat. 3. If equipped, remove the lumbar knob and/or seat back recliner screw and handle. 4. Remove the screws attaching the seat switch bezel and reposition the bezel. 5. Remove the outer trim panel attaching screws and remove the panel from the side of the seat cushion. Page 545 Control Module HVAC: Locations Manual Control Locations View - HVAC Systems - Manual Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 12927 1. Install the ORVM switch, if equipped. 2. Install the inside door handle bezel. 3. Install the door trim panel to the door, as follows: 3.1. Install the panel on the door by placing the upper flange into the belt seal lip. 3.2. Install the rear upper retainer first. 3.3. Install the forward upper retainer second. 3.4. Install the remaining seven retainers. 3.5. Install the forward trim panel retaining bolt first. Do not tighten the bolt. 3.6. Install the rearward trim panel retaining bolt second. 3.7. Tighten the two retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (88 lb in). 4. Install the accessory switch panel. Trim Panel Replacement - Side Front Door Trim Panel Replacement - Side Front Door Tools Required J 36796 Clip Removal Tool Removal Procedure 1. Remove the accessory switch panel. 2. Remove the 2 trim panel retaining bolts. 3. Use the J 36796 in order to release the 9 trim panel fasteners from the door. 4. Remove the trim panel from the door. 5. Remove the inside door handle bezel. 6. Remove the outside rear view mirror (ORVM) switch, if equipped. Installation Procedure 1. Install the ORVM switch, if equipped. 2. Install the inside door handle bezel. 3. Install the door trim panel to the door, as follows: 1. Install the panel on the door by placing the upper flange into the belt seal lip. 2. Install the rear upper retainer first. 3. Install the forward upper retainer second. 4. Install the remaining seven retainers. 5. Install the forward trim panel retaining bolt first. Do not tighten the bolt. Page 7940 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 2634 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Diagrams Door Lock Cylinder Switch - Driver Page 2645 Locations View Page 2973 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 15331 Various symbols are used in order to describe different service operations. Page 11785 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 1759 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 7860 3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic. 4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3). 5. Install the washer and snap ring retaining the motor/encoder rotary position sensor. 6. Install the motor/encoder gasket (1). Page 4197 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 10978 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE Page 4184 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Rearview Mirrors (Outside) - Uncommanded Movement Door Module: All Technical Service Bulletins Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Locations Locations View Page 7387 For vehicles repaired under warranty, use the table. Disclaimer Locations Locations View Body - Liftgate Binding/Improper Fit/Rear Glass Broken Trunk / Liftgate Hinge: Customer Interest Body - Liftgate Binding/Improper Fit/Rear Glass Broken Bulletin No.: 06-08-66-011A Date: November 08, 2006 TECHNICAL Subject: Rear Liftgate Binds, Improper Fit, Broken Liftgate Glass (Install Welds and Bumpers) Models: 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL Supercede: This bulletin is being revised to add part number information. Please discard Corporate Bulletin Number 06-08-66-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the liftgate or the liftgate glass doesn't fit properly. In some extreme cases, the rear liftgate glass may have broken. Cause A couple of welds may have broken around the upper liftgate hinge(s) or a crack may have formed around the inner two welds. Remove the liftgate and inspect the inner to outer panel welds at the upper hinges. Correction Remove the liftgate trim and electrical wiring from the liftgate. Remove the liftgate and liftgate glass from the vehicle. Straighten the sheet metal at the hinges. Drill four 5/16" holes through the inner panel at the four locations shown in the illustration above. Prepare the sheet metal around the four holes for welding. Clamp the inner and out panel together. Page 3673 Electrical Symbols Part 2 Page 11921 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 10743 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Specifications Connecting Rod: Specifications Connecting Rod Cap Bolt First Pass 18 ft. lbs. Final Pass 110 degrees Connecting Rod Connecting Rod Bearing Journal Diameter 2.2337-2.2342 inch Connecting Rod Bearing Journal Out Of Round - Maximum 0.0002 inch Connecting Rod Bearing Bore Diameter 2.3749-2.3755 inch Connecting Rod Inside Bearing Diameter 2.2351-2.2362 inch Connecting Rod Bearing Journal Clearance 0.0008-0.0025 inch Connecting Rod Side Clearance 0.0019-0.0137 inch Connecting Rod Bushing to Pin Clearance 0.0004-0.0007 inch Connecting Rod Inside Bushing Diameter 0.9055-0.9060 inch Page 6188 Page 6824 Disclaimer Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: Customer Interest Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 5477 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14994 Various symbols are used in order to describe different service operations. Page 300 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 4249 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6053 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 5215 Electrical Symbols Part 8 Page 2533 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 7822 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. HVAC Module Assembly Replacement Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement TOOLS REQUIRED ^ J 43181 Heater Line Quick Connect Release Tool ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Remove the I/P carrier. 4. Reposition the heater hose clamps using J 43181. 5. Disconnect the heater hoses from the heater core. 6. Remove the retaining nut (3) from the accumulator (6) at the evaporator (1). 7. Disconnect the accumulator (6) from the evaporator (1). 8. Disconnect the evaporator tube (4) from the evaporator (1). 9. Disconnect all of the electrical connectors to the HVAC module assembly. 10. Remove the HVAC module assembly. INSTALLATION PROCEDURE 1. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary. 2. Install the HVAC module assembly (8). 3. Connect all of the electrical connectors to the HVAC module assembly. Page 4101 Manifold Absolute Pressure (MAP) Sensor OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Engine Controls - SES Lamp ON/DTC P0135 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Locations Locations View Page 14922 Electrical Symbols Part 4 Page 13975 Conversion - English/Metric Page 12295 Page 9844 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6123 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2395 1. Install the air cleaner element (1) onto the air cleaner outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element and air cleaner outlet duct into the lower air cleaner housing/washer solvent tank assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the air cleaner cover/resonator assembly (1). Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator support cover. Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 13486 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts (2) retaining the rear of the floor console bracket to the floor weld studs. Tighten Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the center pillar trim panels. 9. Install the front side door sill plates. 10. Pass the communication interface module electrical connectors through the small hole in the carpet. 11. Pass the body electrical block electrical connectors through the small hole in the carpet. 12. Install the body electrical block. 13. Install the carpet ensuring that the carpet hooks over the left wheelhouse panel stud. Page 9796 C307 Part 2 Page 2652 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 7685 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 7493 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Page 13008 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Page 3268 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 4774 Electrical Symbols Part 8 Page 14758 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15425 Conversion - English/Metric Page 12437 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 13924 Disclaimer Page 9559 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2570 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Page 3905 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 36 Page 6041 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 12068 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 14945 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14139 Sunroof Switch Page 12083 Non-Compatible Garage Door Openers Page 11950 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 50 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 10737 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 4819 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 5604 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the intake manifold. 3. Before removal, clean the fuel rail assembly and the cylinder head with a spray type engine cleaner, GM X-30 A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. 4. Disconnect the fuel pressure regulator vacuum line. 5. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 6. Disconnect the fuel injector harness in-line connector. Page 2809 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. 9. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 10. Install the tire and wheel center cap. Page 12244 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 6719 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 10544 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation Tools Required ^ J39544-KIT Wheel Nut Torque Adapters Caution: Refer to Brake Dust Caution in Service Precautions. Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Important: Penetrating oil effectively removes tight wheels. Apply the oil sparingly to the hub surface, if you use oil. Removing wheels can be difficult, because of foreign material or a tight fit between the wheel center hole and the hub or the rotor.Excessive force, such as hammering on the wheel or the tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. Wheel removal should be performed in the following manner: 1. Tighten all wheel nuts on the affected wheel. Do not torque the wheel nuts. 2. Loosen each wheel nut two turns. 3. Apply quick, hard jabs to the brake pedal in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle from side to side, using the body weight of 1 or more persons. 4. Repeat this procedure if the wheel is still tight. Removal Procedure 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel hub cap, if equipped. 3. Remove the wheel nuts. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly. 5. Clean the wheel nuts, studs, and the wheel and rotor mounting surfaces. Installation Procedure Page 9312 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 2822 Disclaimer Page 5280 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Service and Repair Courtesy Lamp Bulb: Service and Repair COURTESY LAMP REPLACEMENT - INSTRUMENT PANEL REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. IMPORTANT: The courtesy lamp lens assembly can not be removed from the closeout/insulator panel until the bulb is removed. 2. Carefully remove the bulb from the courtesy lamp socket. 3. If removing the lens assembly from the closeout/insulator panel, release the retaining tabs on the lens/socket and push the lens assembly downward. 4. Remove the lens assembly from the closeout/insulator panel. INSTALLATION PROCEDURE 1. Install the lens assembly to the closeout/insulator panel ensuring the tabs are fully seated. 2. Install the bulb to the courtesy lamp socket. 3. Install the left closeout/insulator panel. Page 9560 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Radiator Hose Replacement- Inlet Radiator Hose: Service and Repair Radiator Hose Replacement- Inlet Radiator Hose Replacement- Inlet (Body Vin Code 3) ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: All Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 14434 Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the 3 bolts securing the rear seat cushion latch to the seat pan. Tighten the rear seat cushion latch release bolts to 10 N.m (88 lb in). 2. Install the small loop (1) onto the rear seat cushion latch (2). 3. Install the strap through the opening in the seat pan. 4. Install the rear-seat cushion cover and the pad. 5. Install the rear seat cushion assembly to the vehicle. Seat Cushion Pull Strap Replacement - Rear No. 1 Seat Cushion Pull Strap Replacement - Rear No. 1 Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). Installation Procedure Page 9552 ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio to the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place the new harness under the carpet and reposition the carpeting 27. While lifting the carpet in the rear door area, slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 28. Locate the 8-way connector with the purple CPA. Separate the connector. Remove the CPA from the female side of the connector. 29. Route the new harness under the carpet from the rear of the console to the 8-way connector. 30. Remove the eight wires from the 8-way in line harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Insert the Gray wire into cavity A. ^ Insert the Tan wire into cavity B. ^ Insert the Dark Green wire into cavity C. ^ Insert the Light Green wire into cavity D. ^ Insert the Yellow wire into cavity E. ^ Insert the Brown wire into cavity F. ^ Insert the Light Blue wire into cavity G. ^ Insert the Dark Blue wire into cavity H. 31. Reinstall the CPA, reconnect the 8-way connector, and reattach it to its retaining clip. 32. Cut the wires and terminals from the wires you have removed from the 8-way connector as close to the taped portion of the original wiring harness as possible. 33. Reposition the rear electrical center through the carpet and reposition the carpet. 34. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 35. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 36. Insert the ignition key and turn to the RUN position Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 37. Turn the key OFF. Remove the key. Page 13960 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1701 Electrical Symbols Part 8 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 279 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 2592 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. Page 11381 Disclaimer Page 6090 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 1742 Electrical Symbols Part 8 Cassette Player Care and Cleaning Tape Player: Service and Repair Cassette Player Care and Cleaning TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Kit Follow the recommended cleaning schedule: 1. Clean the cassette player every 15 hours for the best performance. 2. Clean the cassette player every 50 hours in order to prevent damage to the tape head. Clean the following 2 parts on the tape player: - The head - The capstan Leave the tape player in the vehicle, since you can reach the parts through the tape door. Perform this service at least every 50 hours of cassette operation. After 50 hours of tape play, CLN (Clean) appears on the display as a reminder. Although the system will still function when this message is displayed, the following conditions may occur until the head and the capstan are cleaned: - Reduced sound quality - Damage to the cassette tapes After cleaning the cassette tape player, press and hold EJECT for 5 seconds in order to reset the CLN indicator. The radio displays - - - in order to show that the clean feature has been reset. Failure to clean the cassette player regularly may cause the following conditions: - Reduced sound quality - Damage to the cassettes - Damage to the mechanism Keep the cassette tapes correctly stored in their plastic cases away from the following conditions: - Contaminants - Direct sunlight - Extreme heat Failure to correctly store the cassette tapes may cause the following conditions: - Improper operation of the cassette tapes - Premature failure of the tape player The cassettes are subject to wear. The sound quality may degrade over time. Before servicing a tape player, verify that the following conditions exist: - The cassette tape is in good condition. - The tape player is clean. Clean the tape player at least after every 50 hours of use in order to provide optimum performance. The radio displays CLN as a reminder every 50 hours. If a reduction in the sound quality occurs, regardless of when the tape player was last cleaned, play a different cassette tape in order to see if the tape or the tape player is at fault. If the second cassette tape results in no improvement in sound quality, clean the tape player. Page 13233 Optimal results will be obtained by allowing the seal to remain in a compressed state with the glass closed for a period of 48 hours. Parts Information Parts are expected to be available from GMSPO on June 13, 2003. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 760 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 10346 11. Verify the pin can be removed and installed with ease to ensure the correct sensor installation. If the pin cannot be inserted with ease, loosen the sensor fasteners, adjust the sensor, and retighten the sensor fasteners until the pin can be removed and installed with ease. Notice: Failure to remove the air suspension auto level control sensor locating pin will cause damage to the air suspension auto level control sensor. 12. Remove the air spring level sensor locating pin. 13. Perform the sensor calibration for the right side. Raise or lower the vehicle so the left side D-height is 110 mm from the right side of the vehicle. 14. Raise the vehicle off the jackstands and remove the jackstands from under the vehicle. 15. Install the rear tires and wheels. 16. Lower the vehicle. 17. Install the air suspension fuse. 18. Turn the ignition key to the ON position to inflate the rear air springs. 19. After two minutes, turn the ignition key to the OFF position. 20. Recycle the ignition, if needed. 21. Verify and record the D-height. Page 15375 Tachometer: Description and Operation The IPC displays the engine speed based on the information from the PCM. The PCM converts the data from the engine speed sensor to a 2 pulses/engine revolution signal. The IPC uses the engine speed signal circuit (2 pulses/engine revolution) from the PCM in order to calculate the engine speed. If the IPC detects a malfunction in the engine speed signal circuit, the IPC uses the class 2 message from the PCM indicating the engine speed. Page 3858 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1108 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Page 2077 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 5903 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 298 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 4454 Disclaimer Page 4348 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 10884 Control Module HVAC: Locations Manual Control Locations View - HVAC Systems - Manual Page 14211 For vehicles repaired under warranty, use the table. Disclaimer Page 3350 Fuel System Diagnosis - Steps 12-17 Page 11949 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Transfer Case Shift Control Module C1 Page 203 For vehicles repaired under warranty use, the table. Disclaimer Page 10539 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203 - 229 mm (8 - 9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance Page 15547 Page 2625 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood C1 Page 10363 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 8701 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12183 1. Install the speaker to the IP. 2. Connect the speaker electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 3 speaker retaining screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the trim pad. Page 7439 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 3916 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 3348 Fuel Pressure: Testing and Inspection SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Fuel System Diagnosis - Steps 1-3 Page 13489 Carpet: Removal and Replacement Carpet Replacement - Front Carpet Replacement - Front Removal Procedure 1. Disable the SIR. Refer to Disabling the SIR System In SIR. 2. Remove the front bucket seats. 3. Remove the front door sill plates. 4. Remove the center pillar trim panels. 5. Remove the floor console. 6. Remove the floor console bracket. 7. Remove the carpet from the vehicle. Installation Procedure 1. Position the carpet to the floor panel. 2. Feed the front edge of the carpet underneath the instrument panel. 3. Align the holes in the carpet to the seat studs on the floor panel. 4. Position the rear carpet over the edge of the front carpet. 5. Install the floor console bracket. 6. Install the floor console. 7. Install the center pillar trim panels. 8. Install the front door sill plates. 9. Install the front bucket seats. 10. Enable the SIR. Link. Refer to Disabling the SIR System In SIR. Carpet Replacement - Rear (TrailBlazer EXT, Envoy XL) Carpet Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the front seats. 2. Remove the second row rear seats. 3. Remove the third row rear seats. Page 12112 Locations View Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 12510 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 10217 6. Slide the shock dampener (1)over the inner tie rod housing (2) until the front lip of the shock dampener (1) bottoms against the inner tie rod housing (2). 7. Slide the shock dampener (3) forward onto the rack (2). Important: Threads must be clean prior to LOCTITE application. Check the LOCTITE (or equivalent) container expiration date. Use only enough LOCTITE to evenly coat threads. 8. Apply LOCTITE 262 (or equivalent) to the inner tie rod (1) threads. 9. Attach the inner tie rod (1) onto the rack (2). Important: The pipe wrench must be placed at the valve end of the steering gear (5) and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear (5). 10. Maintain the pipe wrench on the opposite end of the rack (5) next to the inner tie rod housing. 11. Place a torque wrench and J34028 on the flats of the inner tie rod housing (1). Tighten the inner tie rod housing to 100 Nm (74 ft. lbs.). 12. Slide the shock dampener (1)over the inner tie rod housing (2) until the front lip of the shock dampener (1) bottoms against the inner tie rod housing (2). 13. Remove the gear from the vise. 14. Install the rack and pinion boot. Page 13882 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 11117 Control Module HVAC: Description and Operation BLOWER MOTOR CONTROL PROCESSOR The blower motor control processor controls the speed of the blower motor by increasing or decreasing the voltage drop on the ground side of the blower motor. The HVAC control module provides a low side pulse width modulated signal to the blower motor control processor over the blower motor speed control circuit. As the requested blower speed increases, the HVAC control module increases the amount of time that the speed signal is modulated to ground. As the requested blower speed decreases, the HVAC control module decreases the amount of time that the signal is modulated to ground. Locations Locations View Page 12334 Page 4319 Electrical Symbols Part 1 Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 5028 Electrical Symbols Part 7 Page 11304 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt Loop Reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 16001 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Specifications Drive/Propeller Shaft: Specifications Propeller Shaft Fastener Tightening Specifications Page 11516 8. Install and secure the headlamp wire harness in the retaining clip (1). 9. Install the grille. 10. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 1604 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Powertrain Control Module (PCM) Replacement Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector retaining bolts (1) in the center of the PCM harness connectors. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Remove the PCM harness connectors (3) from the PCM (2). 3. Remove the PCM mounting nuts and bolts (3). NOTE: Refer to PCM and ESD Notice in Service Precautions. 4. Remove the PCM (2) from the intake manifold. 5. Remove the PCM mounting studs (1) from the intake manifold, if necessary. Page 9375 Fuse Block - Underhood C6 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 13681 Disclaimer Front Axle Actuator Page 14203 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Page 11821 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 14835 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8073 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 11484 Page 10080 Page 13062 5. Remove the 2 check link retaining nuts from the door. 6. Remove the check link assembly through the door access hole. INSTALLATION PROCEDURE 1. Install the check link assembly through the door access hole. Ensure that the position arrow is pointing forward. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 check link retaining nuts to the door. Tighten Tighten the nuts to 7 N.m (62 lb in). Page 286 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Locations Fuel Pump Relay: Locations FUEL PUMP RELAY Locations View Page 12174 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Recall - Tail/Stop Lamp Inspection/Replacement Technical Service Bulletin # 04087 Date: 041116 Recall - Tail/Stop Lamp Inspection/Replacement Product Safety - Tail Lamps/Stop Lamps # 04087 - (Nov 16, 2004) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles. In some of these vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. The center high mounted stop lamp and turn signal functions are not affected and will operate as designed. The loss of one or both of the tail lamp/stop lamps could reduce the vehicle's visibility to following drivers and fail to warn others that the vehicle is braking and/or is stopped, which could lead to a vehicle crash. Correction Dealers are to inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. Vehicles Involved Involved are certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US Page 8492 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 47 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Specifications Lateral Stabilizer Rod: Specifications Rear Axle Brace to the Frame Mounting Nut 70 ft. lbs. Rear Axle Brace and Rear Axle Tie Rod to Rear Axle Mounting Nut 144 ft. lbs. Rear Axle Tie Rod Mounting Bolts 144 ft. lbs. Page 417 Front Passenger Door Module (FPDM) C3 Driver Door Module (DDM) Locations View Page 11888 For vehicles repaired under warranty, use the table. Disclaimer Page 4706 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 982 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 13963 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 3871 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 8484 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 15973 Electrical Symbols Part 1 Locations Locations View Page 4153 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12066 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11980 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 257 Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 3115 10. Disconnect the prop shaft from the front axle pinion yoke. 11. Remove the oil pan drain plug and drain the oil. 12. Unclip the transmission cooler lines from the engine block. 13. Remove the front differential bolts and set aside the front differential. 14. Remove 4 transmission bell housing bolts that are attached to the oil pan. 15. Remove the remaining oil pan bolts. 16. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine. 17. Clean and inspect the oil pan. Installation Procedure Important: The oil pan must be installed within 10 minutes from when sealer was applied 1. Apply a 3 mm (0.12 inch) bead of sealer GM PN 12378521 to the block, rather than the oil pan. Important: When you install the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block. 2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly. 3. Install the oil pan bolts. Page 5976 Electrical Symbols Part 6 Page 8917 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 5837 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 10025 16. Connect the power steering hose assembly to the power steering gear. 17. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (9 ft. lbs.). 18. Remove the drain pan from under the vehicle. 19. Lower the vehicle. 20. Bleed the power steering system. Page 14381 12. Install the front/rear J strips (2,4). 13. Install the side J strips (1,3). 14. Install the seat pan to the seat adjuster frame. 15. Install the 4 retaining nuts to the studs on the underside of the cushion. Tighten Tighten the nuts to 25 N.m (18 lb ft). 16. Install the 3 seat switch bezel screws. Page 5431 Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (Without Special Tool) Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector, at the lowest point in the fuel rail, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of more than 10 percent in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Fuel contaminated with alcohol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Some types of alcohol are more detrimental to fuel system components than others. Alcohol In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. 3. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by white or light brown crystals. Rubber will appear as black and irregular particles. 4. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Page 6360 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 10073 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Locations Locations View Page 12869 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 4638 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Liftglass Ajar Switch Page 14766 Audible Warning Device: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 153 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 2807 7. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 8. Remove the ABS sensor from the wheel hub and bearing. 9. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 10. Remove the wheel hub and bearing from the steering knuckle. 11. Remove the splash shield from the steering knuckle. Installation Procedure Page 13259 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Window Latch Replacement - Lift Gate Window Removal Procedure 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Remove the bolts that retain the latch to the liftgate. 4. Disconnect the electrical connector. 5. Remove the latch from the liftgate. Installation Procedure 1. Position the latch to the liftgate. 2. Connect the electrical connector. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the latch to the liftgate. Tighten the bolts to 10 N.m (89 lb in). 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. Page 9699 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 10306 Page 2839 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Rear Door Tools Required J 36796 Clip Removal Tool Removal Procedure 1. Remove the cover from the trim panel. 2. Remove the 2 retaining screws from the trim panel. 3. Remove the power window switch. 4. Use the J 36796 in order to release the fasteners that retain the trim panel to the door. 5. Remove the trim panel from the door. Installation Procedure 1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated. 2. Install the power window switch. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 retaining screws to the trim panel. Tighten the screws to 2.5 N.m (22 lb in). 4. Install the cover to the trim panel. Page 3693 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5972 Electrical Symbols Part 2 Page 2572 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 43600 ACR 2000 Air Conditioning Service Center ^ J 45037 A/C Oil Injector CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (fart) for the correct amount. Page 15789 Equivalents - Decimal And Metric Part 1 Page 3045 8. Install the engine protection shield and secure the shield with the bolts. ^ Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 9. Install the right and the left lower engine mount nuts. ^ Torque the lower engine mount nuts to 70 Nm (52 ft. lbs.). 10. Lower the vehicle. 11. Install the left shock module. 12. Install the MAP sensor (2). 13. Install the MAP sensor retainer (1) and the electrical connector. Page 10473 Disclaimer Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the two halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. 4. Remove the battery. INSTALLATION PROCEDURE Page 4033 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 8884 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Page 13594 16. If the vehicle is equipped with a sunroof, seat the 6 interlocking strips. 17. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 18. Install the center pillar headliner harness electrical connector to the bussed electrical center, and the block base to the floor panel. 19. Install the headliner harness retaining clips (2) to the rocker panel and the floor panel. 20. Install the headliner harness to the left center pillar. 21. Install the following headliner harness clips to the center pillar: * The center pillar harness clips (1) * The center pillar harness clips (3) * The center pillar harness clips (4) Notice: Refer to Fastener Notice in Service Precautions. 22. Install the ground terminals and the ground bolt (2) to the center pillar. Tighten the bolt to 10 N.m (88 lb in). 23. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right center pillar. 2. Install the navigation antenna cable to the right side door sill attachments. 3. Install the navigation antenna cable to the communication interface module. 24. Install the sunshades to the headliner. 25. If equipped, install the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement - Page 9941 4. Loosen the lower control arm adjustment bolts (1). 5. Adjust the caster and the camber angle by repositioning the lower control arm (2) until the specifications have been met. 6. When the adjustments are complete, hold the lower control arm in position so that the specifications do not change while tightening the lower control arm adjustment bolts. Tighten the lower control arm adjustment bolts to 160 Nm (118 ft. lbs.). 7. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment 1. Loosen the jam nut on the outer tie rod (2). Notice: Care must be taken that the boots are not: twisted when rotating the inner tie rods, or damage to the boots may result. 2. Rotate the inner tie rod (1) to the required toe specification setting. 3. Tighten the jam nut on the outer tie rod. Tighten the outer tie rod jam nut to 75 Nm (55 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 14429 14. Install the seat pan to the seat adjuster frame. 15. Install the 4 retaining nuts to the studs on the underside of the cushion. Tighten the nuts to 25 N.m (18 lb ft). 16. Install the 3 seat switch bezel screws. Seat Cushion Trim Panel Replacement - Rear No.1 Seat Cushion Trim Panel Replacement - Rear No.1 Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat bracket mounting nuts (2). 4. Remove the rear seat bracket. 5. Remove the two bolts (2) securing the support (1) to the seat cushion trim panel. 6. Remove the seat cover J-strips (1) from the seat cushion trim panel (2). Page 4977 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 15143 Conversion - English/Metric Page 4475 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 5225 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 14683 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Inner REMOVAL PROCEDURE 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 12161 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12158 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 6025 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 2919 17. Remove trim tool assembly EN 45680-411 from the engine block. 18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413. 19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413. 20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line. 21. Using a light, illuminate the backside of the straight edge. 22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present of either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 24. Proceed to the next cylinder bore sleeve to be trimmed repeating steps 10-23 if necessary. Parts Information Page 3697 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2227 Window Switch - RR Part 2 Window Switch - RR Part 1 Page 5606 1. Lubricate the new lower injector O-ring seals (4) with clean engine oil. 2. Install the new O-ring seals (4) on the spray tip end of each injector (3). 3. Install the fuel rail assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 4. Install the fuel rail attaching bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Page 5160 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 9924 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 9663 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 11723 Page 15502 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9814 Locations View Page 13720 Conversion - English/Metric Page 11781 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 3144 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 8287 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11327 CHILD RESTRAINT TETHER ANCHOR REPLACEMENT - REAR NO.1 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (1) securing the child tether anchor (2) to the seat cushion frame. 4. Remove the child tether anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the child tether anchor (2) to the seat cushion frame with the bolt (1). Tighten Tighten the child restraint tether anchor bolt to 35 N.m (26 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 16005 Various symbols are used in order to describe different service operations. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 5814 Electrical Symbols Part 7 Specifications Pressure Regulating Solenoid: Specifications Pressure Control Solenoid Bracket to Valve Body Bolt .............................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 8429 For vehicles repaired under warranty, use the table. Disclaimer Page 13409 1. Install the transmission support to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper transmission support to the frame mounting bolts. Tighten the upper transmission support to the frame mounting bolts to 50 N.m (37 lb ft). 3. Install the lower transmission support to the frame mounting bolts. Tighten the bolts to 46 N.m (35 lb ft). 4. Lower the transmission onto the transmission support. 5. Install the transmission mount to the transmission support retaining nuts. Tighten the transmission mount to the transmission support retaining nuts to 46 N.m (35 lb ft). 6. Install the evaporative emission (EVAP) canister. 7. Install the fuel tank shield. 8. Lower the vehicle. Page 6127 Equivalents - Decimal And Metric Part 1 Page 12298 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 12337 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 11826 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 12637 Disclaimer Page 1529 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 13360 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1955 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 12771 2. Install the new assist step skid pad. Ensure all fasteners are fully seated. 3. Repeat the above steps for the opposite side. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. DISCLAIMER Front Wheel Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Bearing Replacement Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the brake rotor. 6. Disengage the wheel drive shaft from the wheel hub and bearing. Place a brass drift against the outer end of the wheel drive shaft in order to protect the wheel drive shaft threads. Sharply strike the brass drift with the hammer. Do not attempt to remove the wheel drive shaft from the wheel hub and bearing at this time. Page 1422 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 13876 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 11004 Housing Assembly HVAC: Service and Repair HVAC Module Case Sump - Auxiliary REMOVAL PROCEDURE 1. Remove the evaporator core-auxiliary. 2. Remove the HVAC module-auxiliary case sump (4) from the HVAC module. INSTALLATION PROCEDURE 1. Install the HVAC module-auxiliary case sump (4) to the HVAC module. 2. Install the evaporator core-auxiliary. Page 11172 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 1326 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 3918 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 484 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the module to the liftgate. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. Page 15224 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 10262 Control Arm: Specifications Upper Control Arm Mounting Bolts 111 ft. lbs. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 12304 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 15707 Electrical Symbols Part 2 Page 15738 Various symbols are used in order to describe different service operations. Page 9118 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 1871 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1399 Electrical Symbols Part 6 Cooling System - Electro-Viscous Fan Clutch Operation Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 2173 Speed Sensor: Specifications NVG126-NP4 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) NVG 226-NP8 Transfer Case Speed Sensors ............................................................................................................ .................................................... 17 Nm (13 ft. lbs.) Page 1255 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 10757 Various symbols are used in order to describe different service operations. Page 753 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 1495 Fuel Tank Pressure (FTP) Sensor Page 14836 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 14390 INSTALLATION PROCEDURE 1. Install the seat back pad to the seat back frame. 2. Install the 6 push pins that retain the seat back pad to the seat back frame. 3. Partially install the seat cover. 4. Install the 3 hog-rings to the reinforcement bar. Page 13152 Hood Latch: Adjustments Hood Latch Adjustment Inspection Procedure 1. Release the primary hood latch in order to inspect the operation of the pop-up spring. 2. Attempt to raise the hood while the hood is in the pop-up position. * The hood should raise without the hood striker binding against the latch. * The secondary latch should engage in order to prevent the hood from being raised. Adjustment Procedure 1. Loosen the bolts retaining the hood latch to the support bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Move the hood latch from side to side until the striker enters the center of the latch assembly. Tighten the bolts retaining the hood latch to the support bracket to 10 N.m (89 lb in). Page 1533 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 12659 Electrical Symbols Part 1 Page 6344 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 856 Disclaimer Page 4321 Electrical Symbols Part 3 Page 3903 Electrical Symbols Part 8 Page 5066 Engine Coolant Temperature (ECT) Sensor Page 7427 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 14744 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3141 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 3542 Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement - Tools Required J 38185 Hose Clamp Pliers - J 46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the hood latch support. 2. Disconnect the transmission cooler lines at the engine and release the lines from the fan shroud. 3. Remove the 2 upper bolts on the fan shroud. 4. Drain the cooling system. 5. Reposition the upper inlet radiator hose clamp using J38185. 6. Remove the upper inlet radiator hose from the radiator. 7. Remove the electrical connector from the shroud. 8. Position the water pump so the bolts are aligned in the vertical. 9. Remove the fan hub nut from the water pump shaft in a counterclockwise rotation. Using the J 46406, in order to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft. Page 4326 Electrical Symbols Part 8 Page 11515 6. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. Tighten Tighten the front end discriminating sensor bolts to 8 N.m (71 lb in). 7. Position the headlamp wire harness (1) to the retaining clip. Page 15607 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 7580 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 1016 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting the windshield wiper module, installing a breathable seal to the vent on the wiper motor cover if applicable, or if necessary, installing a new windshield wiper module. INSPECTION PROCEDURE 1. Using a flashlight, look down through the air inlet screen (1) at the location shown. ^ If the color of the can (2) on the wiper motor is SILVER, no repairs are required on the vehicle. ^ If the color of the can (2) on the wiper motor is BLACK, proceed to the section below titled, REPAIR PROCEDURE. REPAIR PROCEDURE 1. Verify that all of the functions of the wiper system (low, high, delay, etc.) operate properly. 2. Turn the key to the OFF position. 3. Open the hood. Page 14997 Fuel Gauge: Description and Operation The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: ^ The PCM detects a malfunction in the fuel level sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the IPC illuminates the low fuel indicator. Page 11740 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 13950 Door Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 6765 Page 959 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 5210 Electrical Symbols Part 3 Page 4959 Locations View Page 2840 started. Page 2280 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by loosening the lower control arm adjustment bolts and repositioning the lower control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are given under Ride/Trim Height Specifications. 1. For an accurate reading, do not push or pull on the tires during the alignment process. View Of Left Front Wheel From Left Side Of Vehicle 2. Determine the caster angle. View Of Front Wheel From Front Of Vehicle 3. Determine the camber angle. Page 9183 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump Page 378 Electrical Symbols Part 2 Page 11001 8. Connect the heater hoses to the heater core. 9. Install the nuts to the HVAC module studs. Tighten Tighten the nuts to 10 N.m (89 lb in). 10. Remove the cap or tape from the A/C lines. 11. Install the new O-ring seals. 12. Install the nuts (3) to the evaporator core studs. Tighten Tighten the nuts to 20 N.m (15 lb ft). 13. Lower the vehicle. 14. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 15. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fitting of the component using the J 39400-A. Page 15392 Electrical Symbols Part 1 Recall - Front Seat Belt Retractor Defect Technical Service Bulletin # 04037 Date: 040601 Recall - Front Seat Belt Retractor Defect File In Section: Product Recalls Bulletin No.: 04037 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: FRONT SEAT BELT RETRACTOR NONCOMPLIANCE MODELS: 2002 CHEVROLET TRAILBLAZER 2002 GMC ENVOY 2002 OLDSMOBILE BRAVADA Since the inspection procedure in this recall can be performed quickly and easily, and to reduce the inconvenience to the customer, when a customer brings their vehicle into your dealership for this recall, if at all possible, have this inspection performed on the vehicle immediately so that the customer does not have to leave their vehicle at the dealership. If you confirm proper retractor lockup, GM recommends that you demonstrate to the customer that the retractor locks properly. CONDITION General Motors has decided that certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies. These vehicles have a condition where one of the two sensors in the driver's and front passenger's seat belt retractors may be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as during heavy braking, may not operate as intended. If this were to occur, the seat belt may not restrain the occupant as intended during a crash, and could result in injury to the occupant. CORRECTION Dealers are to inspect the driver and front passenger seat belt retractors, and replace them if necessary. Since the inspection is easy to perform, and to reduce customer inconvenience, customers will be sent an inspection procedure with instructions to contact their dealer if a seat belt retractor does not lock while performing the inspection. However, if they desire, they can take their vehicle to their dealer for the inspection. VEHICLES INVOLVED Involved are certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Page 11082 Locations View - HVAC Systems - Automatic Page 8679 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Page 7700 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Locations View Page 2874 Camshaft: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). Installation Procedure 1. Lubricate the hole (1) with engine oil. 2. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten the bolt to 10 Nm (89 in. lbs.). 3. Connect the camshaft position actuator solenoid electrical connector. 4. Install the power steering pump and bolts. 5. Install the drive belt. Page 6349 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 161 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 12029 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4253 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9460 C201 Part 3 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 5015 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 4861 Electrical Symbols Part 5 Page 13958 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4556 Electrical Symbols Part 3 Page 8122 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4624 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 13968 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11252 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Position the side impact sensor (2) to the door. 2. Connect the electrical connector (1) to the side impact sensor (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws which retain the side impact sensor to the door. Tighten Tighten the side impact sensor screws to 8 N.m (71 lb in). 4. Fully seat the water deflector to the door. 5. Install the door trim panel. 6. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 8023 4. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the fill plug threads. 5. Install the fill plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 6. Install the transfer case shield, if equipped. 7. Lower the vehicle. Refer to Vehicle Lifting. Page 738 Electrical Symbols Part 6 Page 2599 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Service and Repair Television / Monitor: Service and Repair VIDEO DISPLAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Do not attempt to service the video display assembly components. The video display is serviced only as an assembly. 1. Turn the ignition switch to the OFF position. 2. Using a plastic flat bladed tool, carefully remove the bolt cover bezel. 3. Fully loosen the two rear retaining bolts. The bolts will remain attached to the video assembly. 4. In order to expose the two front retaining bolts, adjust the video display screen to a full open position. 5. Fully loosen the front retaining bolts. The bolts will remain attached to the video assembly. 6. Close the video display screen. 7. Slowly lower the front of the video assembly to release the retaining fastener (3). 8. Support the video assembly and disconnect the electrical connector (2). 9. Adjust the video assembly in order to release the T-hook (1) from the video player bracket. 10. Remove the video assembly from the vehicle. INSTALLATION PROCEDURE IMPORTANT: Ensure the lock washers are fully seated, completely exposing the bolt threads. Page 1726 Various symbols are used in order to describe different service operations. Page 11953 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 3464 Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the bracket bolt securing the accumulator to the coolant recovery reservoir (1). 3. Move the accumulator out of the way. 4. Remove the coolant hoses from the coolant recovery reservoir and plug the hoses and the coolant recovery reservoir outlets with suitable plugs (2). 5. Remove the nut and bolt securing the coolant recovery reservoir. 6. Remove the coolant recovery reservoir. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant recovery reservoir. Install the retaining bolt to the front wheel house panel. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 2. Secure the coolant recovery reservoir to the wheel house panel with the nut. ^ Tighten the nut to 10 Nm (88 inch lbs.). 3. Install the coolant hose to the coolant recovery reservoir (2). 4. Install the accumulator to the coolant recovery reservoir and secure the accumulator with the bracket and the bolt (1). 5. Install the air cleaner assembly. Page 2432 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Page 11356 Seat Belt: Description and Operation FRONT SEAT BELT SYSTEM OPERATION CAUTION: To help avoid personal injury from unrepaired crash damage to a restraint system, perform the seat belt check for each seat belt system. Replace the seat belt system If there is any doubt about the condition Of system components. 1. The front seat belt system includes a driver and/or passenger seat belt retractor and buckle. 2. The LF seat belt system, includes a seat belt switch in the LF seat buckle which controls a fasten safety belts indicator and a tone alarm. When the LF seat belt is buckled, the LF door is closed, and the ignition switch is in the ON position, the following events will not occur: ^ The tone alarm will not operate. ^ The fasten safety belts indicator will not operate. 3. When the LF seat belt is not buckled, the LF door closed, and the ignition switch is in the RUN position, the following events will occur: ^ The tone alarm will operate for 4 to 8 seconds and then turn OFF. ^ The fasten safety belts indicator will operate for 20 seconds, until the LF seat belt is buckled. ^ Then the fasten safety belts indicator will flash for an additional 55 seconds before turning OFF. To diagnose a failure of the fasten safety belts indicator refer to Symptoms - Seat Belts or the tone alarm, refer to Audible Warnings in Instrument Panel, Gauges and Console. SEAT BELT SYSTEM CIRCUIT DESCRIPTION The fasten safety belts indicator will illuminate when the following conditions occur simultaneously: ^ The ignition switch is in one of the following positions: RUN - BULB TEST - START ^ The LF safety belt is not fastened. The audio fasten safety belt warning alarm, located within the Body Control Module (BCM), also incorporates an indicator within the Instrument Panel Cluster (IPC). The fasten safety belt indicator works in conjunction with the fasten safety belt warning alarm. When the BCM receives a signal that the LF safety belt is unfastened, the BCM sends a signal to the IPC to command ON the fasten safety belt indicator. Page 7266 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 11677 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9970 3. Connect the upper control arm to the steering knuckle. 4. Install upper control arm pinch bolt and nut. Tighten the upper control arm pinch bolt to 40 Nm (30 ft. lbs.). 5. Install the brake hose bracket to the steering knuckle. 6. Install the brake hose bracket retaining bolts. Tighten the brake hose bracket retaining bolts to 10 Nm (7 ft. lbs.). 7. Install the outer tie rod to the steering knuckle. 8. Install the new outer tie rod retaining nut. Tighten the outer tie rod retaining nut to 45 Nm (33 ft. lbs.). 9. Install the wheel hub and bearing. 10. Install the tire and wheel. 11. Lower the vehicle. Page 14869 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Page 14074 Endgate Module (EGM) C2 (XUV) Part 2 Locations Locations View Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 5871 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9800 C312 Part 2 C313 Wheel Alignment Specifications Page 14682 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Page 15821 1. Use the J 43244 in order to install the fog lamp relay to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 6710 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Locations Locations View Page 4783 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 15777 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 1676 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 2798 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Page 4276 Electrical Symbols Part 4 Page 5005 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2(TM). 33. If a control module is replaced the following service procedures must be performed: - The Crankshaft Variation Learn Procedure - The Engine Oil Life Reset Procedure - The Idle Learn Procedure - The Inspection/Maintenance Complete System Set Procedure - The Vehicle Theft Deterrent Password Learn Procedure - The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: Ensure the control module and DLC connections are OK. - Ensure the Techline(TM) operating software is up to date. - Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: Do NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. - The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2(TM) to communicate with the control module. - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: The Off-Board Programming Adapter - The Tech 2(TM) - The control module - The Techline(TM) terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline(TM) terminal, select Service Programming. 3. Select Tech 2(TM), Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(TM) as described on the Techline(TM) terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2(TM), select Service Programming Request Information function. The Tech 2(TM) communicates with the control module and receives the access code. 6. With the Tech 2(TM), exit the Service Programming Request Information. 7. Disconnect the Tech 2(TM) from the Off-Board Programming Adapter. 8. Connect the Tech 2(TM) to the Techline(TM) terminal. 9. Turn ON the Tech 2(TM). 10. With the Techline(TM) terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline(TM) terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline(TM) terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline(TM) terminal automatically loads the calibration files to the Tech 2(TM). 16. After the download is complete, turn OFF the Tech 2(TM) 17. Disconnect the Tech 2(TM) from the Techline(TM) terminal. 18. Connect the Tech 2(TM) to the Off-Board Programming Adapter. 19. With the Tech 2(TM), select Service Programming. Page 15412 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 2930 10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block. 11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 Nm (15 lb ft). 12. Fasten drive adapter EN 45680-866 (1) into the drill chuck. 13. Connect a compressed air supply 517-862 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411. 16. Turn off the compressed air valve (2). 17. Remove trim tool assembly EN 45680-411 from the engine block. 18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413. 19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413. Page 4642 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 11138 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Left REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Page 2266 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 5595 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 2922 Cylinder Liner: Service and Repair The content of this article reflects the changes identified in TSB 04-06-01-022B Bulletin No. 04-06-01-022B Date: October 24, 2005 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet Trailblazer 2004-2006 Chevrolet Colorado 2002-2006 GMC Envoy 2004-2006 GMC Canyon 2002-2004 Oldsmobile Bravada with 2.8L, 3.5L or 4.2L Engine (VINs 8, 6, 5 - RPOs LK5, L52, LL8) Cylinder Bore Sleeve Removal Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-400, through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller EN 45680402 will occur. Page 12307 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 14984 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 825 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) Part 1 Page 12293 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 7778 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 14531 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Page 1288 Miniwedge (Door Jamb Switch) - Liftgate Page 15249 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Page 13890 Page 10986 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the nut from compressor hose connection in driver wheel opening. 12. Remove the O-ring seals. 13. Cap or plug all of the open connections. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor discharge hose nut. Tighten Tighten the hose nut to 28 N.m (21 lb ft). 4. Install the compressor hose to the connector in driver wheel opening. 5. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 12542 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 13012 Page 4053 Intake Air Temperature (IAT) Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 12540 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 14952 Conversion - English/Metric Page 11799 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 6372 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 2422 1. Install the O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Page 5312 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Page 15665 Electrical Symbols Part 3 Page 8720 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 6901 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 3886 IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2(TM), select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 2214 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vapor Pipe) Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vapor Pipe) REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) vapor pipe at the fill limiter vent valve (3). 3. Disconnect the EVAP vapor pipe from the front rollover valve (5). 4. Remove the front retaining clip (6) from the fuel and EVAP pipes and remove the EVAP vapor pipe. 5. Disconnect the EVAP vapor pipe from the fill limiter vent valve (3). 6. Disconnect the EVAP vapor pipe from the rear rollover valve (2). 7. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Connect the fuel tank vapor pipe to the rear rollover valve (2). 2. Connect the fuel tank vapor pipe to the till limiter vent valve (3). 3. Connect the EVAP vapor pipe to the till limiter vent valve (3). 4. Install the front clip (6) to the fuel and EVAP pipes at the front of the fuel tank. 5. Connect the EVAP vapor pipe to the front rollover valve (5). 6. Install the fuel tank. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 8335 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 104 Page 4725 Powertrain Control Module (PCM) C2 Part 2 Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 12294 Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) Page 11909 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 3017 Accessory Drive Belt Routing Page 5569 Electrical Symbols Part 3 Page 13954 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 143 Page 15356 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15004 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 3991 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 5699 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 4701 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 937 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 11564 Antenna, Navigation: Service and Repair NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Ensure the ignition is in the OFF position. 2. Remove the electrical connector from the antenna. 3. While maintaining a parallel angle to the windshield, remove the antenna from the bracket by sliding the antenna away from the headliner. INSTALLATION PROCEDURE 1. Position the antenna to the bracket. 2. While maintaining a parallel angle to the windshield, install the antenna to the bracket by sliding the antenna towards the headliner. Ensure the antenna is fully seated to the bracket. 3. Install the electrical connector to the antenna. Page 1877 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Audio/A/C - Settings Change While Driving Body Control Module: Customer Interest Audio/A/C - Settings Change While Driving Bulletin No.: 03-08-44-002A Date: July 22, 2003 TECHNICAL Subject: Radio and/or HVAC Systems Change While Driving (Reprogram Body Control Module) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Supercede: This bulletin is being revised to correctly state the module that requires reprogramming in the Correction section. Please discard Corporate Bulletin Number 03-08-44-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the radio and HVAC settings change while driving down the road. However the seat does not move. Cause Due to the position of the memory buttons on the driver's door pad, a customer may inadvertently depress a memory button. Correction A new software package has been developed. The new software will not allow the radio and HVAC settings to change when the transmission shift lever is in any gear other than Park. Reprogram the Body Control Module using the normal SPS reprogramming procedure (TIS version 1.0 released January 2003, or newer). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9566 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 8961 Page 12228 Page 12987 6. Install the water deflector. 7. Install the door trim panel. Page 3424 Spark Plug: Specifications Ignition System Specifications Page 3590 Electrical Symbols Part 2 Page 8834 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 4640 Conversion - English/Metric Page 11797 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 5329 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 14107 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6393 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 6128 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 14929 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 15521 Various symbols are used in order to describe different service operations. Page 4484 Spark Plug: Specifications Ignition System Specifications Page 9011 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder Replacement Removal Procedure Page 12061 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Body - Center Mount Brake Lamp Applique loose Center Mounted Brake Lamp: Customer Interest Body - Center Mount Brake Lamp Applique loose Bulletin No.: 01-08-66-007C Date: August 27, 2007 TECHNICAL Subject: Center High-Mount Stop Lamp (CHMSL) Applique Loose (Re-Tape Applique) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to include additional model years and change step 7 in the procedure. Please discard Corporate Bulletin Number 01-08-66-007B (Section 08 - Body and Accessories). Condition Some customers may comment that the CHMSL applique is loose on the liftgate glass. Cause A poor bonding of the double-sided adhesive tape between the CHMSL applique and the liftgate glass may cause this condition. Correction Re-tape the CHSML applique to the liftgate glass using the following service procedure: Open the liftgate glass. Remove the screws that retain the applique to the liftgate glass. Do not damage the applique or the liftgate glass when removing the applique from the liftgate glass. With a flat-bladed tool, carefully remove the applique from the liftgate glass. Remove the CHMSL harness grommet from the roof panel. Disconnect the CHMSL harness connector. Place a clean fender cover on a suitable working surface and place the applique on the fender cover. Remove the old adhesive from the underside of the applique. (For Saab Only Remove the two screws from the CHMSL and remove the CHMSL from the applique. Remove all the ribs from the back side of the applique as seen in illustration above. Clean the applique and the CHMSL with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent to the CHMSL lens as seen in the illustration below and install the two screws and tighten). Tighten Page 3309 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil pressure switch. ^ Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 5150 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter A/C - Inoperative Rear A/C Controls, DTC B0150 Control Assembly: All Technical Service Bulletins A/C - Inoperative Rear A/C Controls, DTC B0150 File In Section: 01 - HVAC Bulletin No.: 02-01-39-003A Date: July, 2002 TECHNICAL Subject: Inoperative Rear HVAC Controls and/or DTC B0150 (Replace Rear HVAC Control) Models: 2002 Chevrolet TrailBlazer EXT 2002 GMC Envoy XL with Automatic HVAC Auxiliary Temperature Control (RPO CJ2) Built in May 2002 or Prior This bulletin is being revised to add service procedures and parts and warranty information. Please discard Corporate Bulletin Number 02-01-39-003 (Section 01 - HVAC). Condition Some customers may comment on an inoperative rear climate control panel. The controls may appear to not respond or to have very slow response for approximately one minute from starting the vehicle with limited temperature or mode range of the control. Diagnostic Trouble Code (DTC) B0150 may be stored in History. Some customers may associate this condition with a recent servicing that required the battery to be disconnected. Cause When the battery is disconnected from the vehicle for any reason, at the first key on the rear HVAC controller will reset and perform a test sequence, sweeping the temperature and mode doors to the full range of their travel. If during this test one of the rear HVAC module doors runs beyond the expected range, DTC B0150 will set. This code will disable the rear HVAC control. Due to production variances, the mode and temp doors may be traveling beyond their programmed range. Correction A revised rear HVAC controller has been released that eliminates DTC B0150 and has updated programming to allow for a greater expected range of motion. Vehicles built in April 2002 or prior that exhibit the above condition may be repaired using the following procedure. Vehicles built during May 2002 may have been assembled with the revised auxiliary temperature control panel. On step 1 of the following procedure, confirm the part number on the sticker attached to the rear auxiliary climate control panel. If the revised part number from the chart below is already installed, this bulletin does not apply to that vehicle. Use the following procedure to replace the rear HVAC controller: 1. Remove the rear HVAC controller by reaching in from the cupholder on the back of the floor console and pushing the controller out. 2. Disconnect 1 electrical connector from the rear of the HVAC controller. 3. Connect 1 electrical connector to the revised HVAC controller. 4. Install the rear HVAC controller by pushing inward until fully seated. 5. Start the engine and allow approximately one minute for the system to run its initial tests. Confirm the proper operation of the rear controller. Parts Information Parts are currently available from (3MSPO. Warranty Information Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8931 Notice: Whenever the rotor has been separated from the axle flange, clean any rust or foreign material from the mating surface of the axle flange and brake rotor. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Important: If the brake rotor is not going to be replaced but just removed from the front hub to be refinished, mark the brake rotor left or right and relationship of the brake rotor and a wheel stud. In doing so, is will reduce the possibility of vibration in the brake system. 9. Remove the brake rotor. 10. Using the J 42450-A, clean the brake rotor to rear axle flange contact area. 11. Refinish the rotor if necessary. Installation Procedure 1. Clean the park brake shoes using denatured alcohol. 2. Dry the park shoes using non-lubricated, filtered air. 3. Lubricate the contact area between the park brake shoe and the backing plate with high temperature silicone brake lubricant. Page 2920 Warranty Information Page 10909 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 12418 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 14440 1. Install the seat cushion panel on the pad and cover. 2. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 3. Install the pull handle (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two rear seat cushion bolts (2). Tighten the rear seat cushion bolts to 11 N.m (97 lb in). Seat Cushion Trim Panel Replacement - Rear No.1 (TrailBlazer EXT, Envoy XL) Seat Cushion Trim Panel Replacement - Rear No.1 (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat bracket mounting nuts (2). 4. Remove the rear seat bracket. 5. Remove the two bolts (2) securing the support (1) to the seat cushion trim panel. Page 4313 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 12313 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 9767 Multiple Junction Connector: Diagrams C200 - C203 C201 C201 Part 1 Floor Shift Control Replacement Shifter A/T: Service and Repair Floor Shift Control Replacement Floor Shift Control Replacement Removal Procedure 1. Remove the front floor console. 2. Disconnect the shift lock control solenoid wiring harness. 3. Remove the end of the range selector cable (1) from the transmission control ball stud. 4. Remove the range selector cable (2) from the floor shift control. 5. Remove the transmission control bolts. 6. Remove the transmission control. Installation Procedure Page 5317 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 3318 5. Remove the top chain guide bolts. 6. Remove the top chain guide. 7. Remove the exhaust camshaft position actuator bolt. 8. Remove the exhaust camshaft position actuator. 9. Remove the intake camshaft sprocket bolt. 10. Remove the intake camshaft sprocket. 11. Remove the timing chain. 12. Remove the crankshaft sprocket. 13. Remove the cylinder head access hole plugs. Cooling System - Electro-Viscous Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Cooling System - Electro-Viscous Fan Clutch Operation Bulletin No.: 06-06-02-003 Date: February 14, 2006 INFORMATION Subject: Operating Characteristics of the Electro-Viscous (EV) Fan Clutch and Diagnostic Tips for Cooling Fan Noise, Delayed Transmission Shifts and/or Engine Revving Too High Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X with 4.2L I-6, 5.3L V-8 or 6.0L V-8 Engine (VINs S, P, M, H - RPOs LL8, LM4, LH6, LS2) Date/VIN Breakpoints for Vehicles with New EV Fan Clutch Vehicles built after and including the Date or VIN Breakpoints listed in the table shown are equipped with the new electro-viscous (EV) fan clutch. Vehicles of any model year listed in "Models Affected" with labor code J3390 (claimed after June 8, 2005) with P/N 15293048 in Claim History may also be equipped with this new EV fan clutch. After having service for poor HVAC performance and/or engine cooling performance, some vehicles may exhibit fan noise, delayed transmission shifts, or the engine revving too high. These conditions may be caused by expected operating characteristics of the new design electro-viscous (EV) fan clutch. This new design EV fan clutch has been installed on production vehicles from the end of 2005 model year production (June 2005) and all 2006 model year vehicles. The new design EV fan clutch may also be present on vehicles serviced with this new part per Corporate Bulletin Number 04-01-38-019A or for other service related conditions. The updated design of the electro-viscous (EV) fan clutch helps improve A/C performance but may also produce some additional fan engagement noise. Important: Unless a specific issue is identified by proper SI diagnosis, do NOT replace a fan clutch for fan noise. Page 1820 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. Procedures Body Control Module: Procedures IMPORTANT: If the module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not property configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to Programming Theft Deterrent System Components in Theft Deterrent for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 10024 4. Install the power steering hose assembly to front crossmember bracket mounting bolt. Tighten the power steering hose assembly to front crossmember bracket mounting bolt to 10 Nm (7 ft. lbs.). 5. Install the power steering hose assembly to frame brackets retaining bolts. Tighten the power steering hose assembly to frame brackets retaining bolts to 10 Nm (7 ft. lbs.). 6. Connect the power steering hose assembly bracket to the wheel well. 7. Install the power steering hose assembly bracket retaining bolt at the wheel well. Tighten the power steering hose assembly bracket retaining bolt at the wheel well to 10 Nm (7 ft. lbs.). 8. Install the fuse block. 9. Install the battery tray. 10. Connect the fuse block harnesses to the wiring loops. 11. Raise the vehicle. Refer to Vehicle Lifting. 12. Install the power steering return hose and the power steering cooler hose to the power steering cooler. 13. Remove the power steering gear oil seals from the power steering gear using J44586. Notice: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 14. Clean the power steering gear inlet and outlet ports of any debris. 15. Install the power steering gear oil seals to the power steering gear using J44586. Capacity Specifications Refrigerant System Capacities Page 9658 Fuse Block - Rear (Short Wheelbase, Body Type VIN 3) Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: Recalls Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5443 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 12676 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 9723 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Locations Locations View Page 2335 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 12541 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 2571 Refrigerant: Service Precautions CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 10709 Air Temperature Sensor Assembly - Inside Page 407 Equivalents - Decimal And Metric Part 1 Page 14749 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. HVAC Systems - Manual Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Manual A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 2490 Disclaimer Page 2408 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Page 14262 1. Install the seat back. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 3. Install the SIR harness (2) to the seat clips (1,4). 4. Connect the gray lumbar electrical connector (5), if equipped. 5. Connect the black electrical connector (3) to the seat belt buckle. 6. Connect the black electrical connector (6) to the seat back harness. 7. Install the seat belt buckle to the seat with the nut. Tighten the seat belt buckle nut to 55 N.m (41 lb ft). 8. Install the seat cushion trim panel. 9. Install the front bucket seat assembly to the vehicle. Page 10206 Steering Wheel: Service and Repair "For information regarding this component please refer to steering column service and repair" Page 8849 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 13574 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. NOTE: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the instrument panel (IP) trim pad. 10. Open the IP compartment door and lower the door to the full down position. 11. Disconnect the coax cable (2) and the headliner harness electrical connector (1), located near the bottom of the HVAC blower motor. 12. Remove the lower rosebud (2) that fastens the headliner harness to the cowl. 13. Remove the 3 clips (1) retaining the headliner harness to the right windshield pillar. 14. Attach a mechanic's wire to the end of the headliner harness. 15. The wire harness is located in the cowl insulation access hole, behind the IP. In order to remove the wire harness, grasp the headliner harness near the bottom of the windshield and carefully pull upward. 16. Leaving the mechanic's wire positioned behind the IP, remove the headliner harness from the mechanics wire. 17. Remove the video display. 18. If equipped, remove the front and rear overhead console. 19. Remove the sunshades from the headliner. 20. If equipped with OnStar(R), perform the following procedure: 20.1. Disconnect the navigation antenna cable from the communication interface module. Page 5792 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 6712 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8860 Page 5277 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 1613 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 6067 For vehicles repaired under warranty, use the table. Disclaimer Page 11978 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 16000 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 3926 Equivalents - Decimal And Metric Part 1 Powertrain Control Module (PCM) Replacement Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector retaining bolts (1) in the center of the PCM harness connectors. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Remove the PCM harness connectors (3) from the PCM (2). 3. Remove the PCM mounting nuts and bolts (3). NOTE: Refer to PCM and ESD Notice in Service Precautions. 4. Remove the PCM (2) from the intake manifold. 5. Remove the PCM mounting studs (1) from the intake manifold, if necessary. Page 14799 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 5977 Electrical Symbols Part 7 Page 12747 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 6. Install the rear electrical center cover. 7. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 11226 1. Install the SDM to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the SDM to the floor panel. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Connect the electrical connectors (2) to the SDM (1). 4. Return the carpet to the fully installed position. 5. Install the console mounting bracket to the floor panel. 6. Install the floor console. 7. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Page 1332 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 3959 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5101 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 1816 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 1614 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 11860 Labor Time Information Page 7333 14. Remove the steering knuckle from the upper control arm. 15. Remove the left and right front wheel drive shafts from the front drive axle. 16. Relocate and secure the left and right front wheel drive shafts to the frame. 17. Using mechanics wire or hook, support the front shock modules and steering knuckle. Page 15095 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 1313 Electrical Symbols Part 8 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 15978 Electrical Symbols Part 6 Page 1159 Page 4872 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 12069 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 7331 2. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody. 3. Drain the engine of oil. 4. Drain the front drive axle. Refer to Lubricant Change. 5. Remove the front propeller shaft from the front axle. 6. Wrap the bearing caps with tape in order to prevent the loss of the roller bearings. 7. Remove the ABS wiring harness from the retainers. 8. Remove the brake hose retaining bolts. 9. Remove the front drive axle vent hose. Page 9678 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 6043 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 8437 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 12833 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper Removal Procedure 1. Remove the backup lamp socket assemblies from the backup lamp housings. 2. Remove the lower fascia push-pins. 3. Remove the screws from the rear wheelhouse flanges. 4. Remove the upper retaining bolts from the back of the fascia. 5. Remove the fascia from the vehicle. Installation Procedure Page 11942 Page 7140 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 6172 Spark Plug: Service and Repair Spark Plug Replacement Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 8358 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 14927 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 6785 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 15974 Electrical Symbols Part 2 Page 897 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 7205 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 11722 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 5387 5. Remove the 2 resonator to engine bolts (4) from the air cleaner outlet resonator (5). 6. Lift up the front of the air cleaner outlet resonator (2). 7. Disconnect the crankcase clean air hose from the valve cover port. 8. Disconnect the crankcase clean air hose from the air cleaner outlet resonator (2). Installation Procedure Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 293 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 15127 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Malfunction Indicator Lamp (MIL) Always On - Steps 1-6 Page 11483 SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 4425 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 7567 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11794 A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Page 4623 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 12566 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 6181 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) Page 4201 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 324 1. Position the VCIM bracket to the seat bracket. 2. Slide the VCIM bracket forward until the retaining tabs become locked to the seat bracket. 3. Ensure the retaining tab (1) on the VCIM bracket is properly seated. 4. Install the communication interface module. 5. Position the right second row seat to a passenger position. Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 16056 Parts are currently available from GMSPO. Disclaimer Page 14368 5. Remove the rear seat belt anchor nut (2). 6. Unhook the J-strips (2) from the bottom of the seat back cover (1). 7. Remove the two push pins (1) from each side of the seat back. 8. Pull the seat cover forward through the opening between the seat cushion and the seat back. Page 8440 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 8839 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15301 Electrical Symbols Part 3 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 4149 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 12612 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 12237 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 1450 Electrical Symbols Part 4 Page 12067 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 10101 Electrical Symbols Part 1 Page 4561 Electrical Symbols Part 8 Page 4207 Various symbols are used in order to describe different service operations. Page 1702 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15959 High Beam Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the high beam relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the high beam relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 14633 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 8996 Removal Procedure Caution: Refer to Brake Dust Caution in Cautions and Notices. Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Important: The following service procedure covers vehicles equipped with both the single and dual piston calipers. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the front tires and wheels assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Clean all dirt and foreign material from the brake hoses and the brake pipes. 4. Using a backup wrench on the brake pipe fitting, disconnect the brake pipe from the brake hose hose. Important: Install a plug or cap in the brake pipe to the exposed brake pipe fitting end in order to prevent fluid loss and contamination. 5. Disconnect the brake pipe fitting from the flex brake hose at the frame. 6. Remove the front brake hose retainer at the frame bracket. 7. Remove the hose front flex brake hose bolt and gaskets from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove the copper gaskets from the brake hose bolt. These gaskets maybe stick to the brake caliper or the brake hose bolt Installation Procedure Important: DO NOT reuse the old copper gaskets. Always use NEW metal copper gaskets. Description and Operation Power Window Lockout Switch: Description and Operation POWER WINDOW LOCKOUT OPERATION The DDM contains a window lockout switch that is responsible for the disabling of all the passenger windows from the individual passenger window switches. When the window lockout switch is activated, the DDM transmits a Class 2 message indicating that a window lockout request has been received. When the PDM receives this message, it will disable the power window motor up and down circuits. When the BCM receives this message, it will interrupt the up and down relay coil feed voltage for both rear doors. Once activated the lockout feature will remain in effect until the ignition switch is cycled or the DDM receives another power window lockout switch activation. Fog Lamp Relay Replacement (RPO T96) Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T96) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood junction block. 3. Use the J 43244 in order to remove the fog lamp relay (1) from the underhood junction block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the fog lamp relay (1) to the underhood junction block. 2. Install the protective covers to the underhood junction block. 3. Close the hood. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 14838 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 651 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 4162 Various symbols are used in order to describe different service operations. Page 10523 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 1603 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 5258 Electrical Symbols Part 6 Page 13009 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Page 12341 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 14058 Memory Seat Module - Driver C4 Page 474 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the seat control module to the seat pan. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 1736 Electrical Symbols Part 2 Page 8756 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 11907 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 15507 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 10050 Page 4369 For vehicles repaired under warranty, use the table. Disclaimer Specifications Power Steering Fluid Cooler: Specifications Power Steering Cooler Mounting Bolts 15 ft. lbs. Page 15901 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 1110 Seat Adjuster Switch - Driver (W/O Memory Seat) Page 13090 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 14294 3. Install the switch bezel to the seat with the 3 screws. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE Page 8735 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 4797 Equivalents - Decimal And Metric Part 1 Page 5558 Fuel System Diagnosis - Steps 4-11 Page 1425 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 12245 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 9770 C203 Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 12176 Conversion - English/Metric Page 8018 Fluid - Transfer Case: Fluid Type Specifications Transfer Case ............................................................................................................................................................. AutoTrak II Fluid GM P/N 12378508 Page 379 Electrical Symbols Part 3 Page 3149 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 14380 6. Install the 11 hog rings to the top side of the cover and pad. 7. Install the 2 hog rings (1) to the bottom rear side of the cover and pad. 8. Press the seat cover hook and loop retaining strips together by running your hand firmly over the seat cover. 9. Connect the seat cushion heater electrical connector. 10. Install the seat electrical harness to the seat pan. 11. Install the SIR electrical harness (2) to the seat pan. Page 2951 Important: The crankshaft balancer does not have a key-way; so the crankshaft could turn when tightening, causing an improper torque. Make sure to follow the installation procedure to prevent damage. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the torque converter access plug in the dry part of the oil pan. 3. Use the torque converter holding tool from the J 44226 kit and secure the torque converter while tightening the crankshaft balancer. 4. Install a new crankshaft balancer shim GM P/N 12573950 over the crankshaft snout, against the crankshaft gear. 5. Using the J41478 install and seat the crankshaft balancer. 6. Remove the J 41478. Notice: Refer to Fastener Notice in Service Precautions. 7. While still holding the flywheel, install the balancer washer and the bolt. ^ Tighten the crankshaft balancer bolt to 150 Nm (110 ft. lbs.). Use the J 36660-A in order to tighten the balancer bolt an additional 180°. 8. Remove the torque converter holding tool. 9. Install the torque converter access plug into the oil pan. 10. Lower the vehicle. 11. Install the drive belt. 12. Install the cooling fan and shroud. 13. Install the hood latch support. 14. Install the radiator diagonal brace. 15. Install the grill. 16. Install the radiator air intake baffle. Specifications Compressor/Pump: Specifications Air Spring Compressor to Frame Mounting Bolts 18 ft. lbs. Page 4238 Electrical Symbols Part 7 Page 15545 16532714 Buick and Oldsmobile --New P/N 16532715 GMC --New P/N 16532716. ^ If the part number printed on a circuit board IS one of the part number listed above, then the circuit board is the new design and does NOT need to be replaced. ^ If the part number printed on a circuit board is NOT one of the part numbers listed above, then the circuit board is the old design and MUST BE REPLACED. Proceed to the next step if either circuit board needs to be replaced. 5. Turn on the tail lamps, directional signals, etc. and determine if there are any bulbs that require replacement. 6. Disconnect the electrical connector from the circuit board being replaced. 7. Remove the three screws attaching the circuit board to the tail lamp and remove the circuit board. 8. Install a NEW stop lamp bulb in a NEW circuit board. ^ On Chevrolet, Buick, and Oldsmobile vehicles, the stop lamp bulb is located in the UPPER (top) socket in the circuit board. ^ On GMC vehicles, the stop lamp bulb is located in the LOWER (bottom) socket in the circuit board. 10. Important: This recall will cover the cost of replacing the stop lamp bulb(s). All other bulbs that require replacement are to be submitted under the normal warranty operation, if applicable. 11. Transfer the remaining bulbs from the old circuit board to the new circuit board. Replace any burned out bulbs. 12. Connect the electrical connector to the new circuit board(s). 13. Turn on the tail lamps, directional signals, etc. and verify that all bulbs are functional. 14. Install the circuit board to the tail lamp and install the three screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 15. Install both the left and the right tail lamp assemblies to the body and install the screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 16. Close the liftgate. Page 8149 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Diagram Information and Instructions Speaker: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 12538 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 12514 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 2192 Electrical Symbols Part 1 Page 7682 Page 7837 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 756 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4281 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12534 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 11911 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 12071 Equivalents - Decimal And Metric Part 2 Arrows and Symbols P/S Pump Flow Control Valve Replacement - Off Veh (CB Series) Power Steering Pump: Service and Repair P/S Pump Flow Control Valve Replacement - Off Veh (CB Series) Power Steering Pump Flow Control Valve Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Remove the connector and fitting assembly (4). 2. Remove the O-ring seal (3). 3. Remove the control valve assembly (3) and the flow control spring (2) from the pump housing assembly (1). Assembly Procedure 1. Install the flow control spring (2) to the pump housing assembly (1). 2. Install the control valve assembly (3) to the flow control spring (2). Page 3428 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 12175 Various symbols are used in order to describe different service operations. Page 15352 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 3683 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 10685 Tighten the screw to 1.9 N.m (17 lb in). 6. Install the headliner 7. Install the right rear quarter trim. Page 3431 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 1670 Conversion - English/Metric C100 - C105 Multiple Junction Connector: Diagrams C100 - C105 C100 C100 A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: Customer Interest A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Diagrams Cargo Lamp Page 15317 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 2272 Page 5175 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 4260 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 3445 1. Install a new water pump gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump and secure the water pump with the bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 3. Install the water pump pulley. 4. Install the water pump pulley bolts. 5. Using the J 41240, secure the water pump pulley while tightening the water pump pulley bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J41240. 7. Install the drive belt. 8. Install the fan and the shroud. 9. Fill the cooling system with the specified coolant and concentration. 10. Inspect for leaks. Transmission Extension Housing Rear Oil Seal Replacement Seals and Gaskets: Service and Repair Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 14755 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Page 4981 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 14844 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 10287 1. Install the transmission support to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper transmission support to the frame mounting bolts. Tighten the upper transmission support to the frame mounting bolts to 50 N.m (37 lb ft). 3. Install the lower transmission support to the frame mounting bolts. Tighten the bolts to 46 N.m (35 lb ft). 4. Lower the transmission onto the transmission support. 5. Install the transmission mount to the transmission support retaining nuts. Tighten the transmission mount to the transmission support retaining nuts to 46 N.m (35 lb ft). 6. Install the evaporative emission (EVAP) canister. 7. Install the fuel tank shield. 8. Lower the vehicle. AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 1323 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 14625 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 15985 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 11977 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 3990 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery terminal. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. Refer to Generator Replacement in Starting and Charging. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. NOTE: Replacement components must be the correct pan number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 10472 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 12995 11. Remove the feed wire (1) from the hinge. 12. Install and hand tighten the 2 remaining bolts. Notice: Refer to Fastener Notice in Service Precautions. 13. Align the hinge to the original scribe location. Tighten the 4 bolts to 25 N.m (18 lb ft). 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). 16. Refinish as necessary. 17. Install and align all of the related panels and components. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 4020 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 6472 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 12447 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 5268 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5125 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 11782 AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 10643 position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. AUXILIARY CONSOLE MODE ACTUATOR The auxiliary console mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. Air Distribution - Auxiliary Control The auxiliary HVAC system provides ventilation for the rear seat occupants. The auxiliary mode actuator shares a control circuit with the auxiliary air temperature actuator.The auxiliary mode is controlled by a rotary knob on the auxiliary HVAC control module. If change of position is required for both actuators, then the auxiliary HVAC control module positions the auxiliary air temperature actuator first. All control circuits for the auxiliary actuators are at a low voltage potential until a change of position is required. The module then applies a high voltage potential to the appropriate control circuit, which will rotate the actuator. Air Temperature Actuator AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5 wire bi-directional electric motor that incorporates a feed back potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AUXILIARY AIR TEMPERATURE ACTUATOR - VIN 6 The auxiliary air temperature actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, position signal, and two control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits. Page 7630 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9497 C800 Locations Sunroof / Moonroof Module: Locations Locations View Page 1342 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 3. Disconnect the electrical connector from the sensor. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Page 10726 Electrical Symbols Part 2 Page 5144 Electrical Symbols Part 7 Page 14972 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 12230 Page 15415 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Wheel Alignment Specifications AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 14947 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 15345 Electrical Symbols Part 6 Procedures Head Rest: Procedures Head Restraint Replacement - Front Seat REMOVAL PROCEDURE 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. INSTALLATION PROCEDURE 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Head Restraint Guide Replacement - Front Seat REMOVAL PROCEDURE Page 4668 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7408 Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 41048 Swage Clamp Tool - J 8059 Snap Ring Pliers Disassembly Procedure 1. Place the halfshaft in a vise. 2. Place protective covers over the vise jaws. 3. Use a hand grinder to cut through the swage rings (2). Do not damage the outer race. 4. Compress the seal on the halfshaft and away from the CV joint outer race (1). 5. Wipe all grease away from the face of the CV joint. Page 6696 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 13531 Interior in Roof. Installation Procedure 1. If replacing the console, install the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Interior in Roof. 2. If replacing the console, install the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 3. If replacing the console, install the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 4. If replacing the console, install the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 5. If replacing the console, install the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. Position the console to the roof panel. 7. Connect the electrical connectors as needed. 8. Seat the front retaining tabs. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the 2 screws retaining the console to the roof panel. Tighten the screws to 1.2 N.m (10 lb in). Overhead Console Replacement - Rear Overhead Console Replacement - Rear Removal Procedure 1. Remove the 4 screws that retain the rear console to the roof panel. 2. Lower the rear console from the headliner. 3. Remove the rear console from the vehicle. Installation Procedure Page 5726 Electrical Symbols Part 4 Page 788 Electrical Symbols Part 2 Interior - Passenger Seat Belt Too Tight Seat Belt Retractor: All Technical Service Bulletins Interior - Passenger Seat Belt Too Tight File In Section: 09 - Restraints Bulletin No.: 02-09-40-003 Date: September, 2002 TECHNICAL Subject: Passenger Seat Shoulder Belt Too Tight or Cinches Up (Replace Passenger Seat Belt Retractor Assembly) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition Some customers may comment that the passenger front seat shoulder belt is too tight or cinches up during buckle-up. This condition is more prevalent when the occupant is of larger stature and may also occur if the occupant, while wearing the belt, performs large unusual movements. Cause The child seat locking mechanism of the Automatic Locking Retractor (ALR) may be engaging when the belt is extended to its full length upon fastening. Belt system is functioning as designed. Correction A new passenger seat retractor assembly has been released for service with additional 250 mm (9.84 in) of length to the belt to improve this condition. Replace the passenger seat retractor assembly. Refer to the Front Seat Belt Replacement procedure in the Seat Belts sub-section of the Service Manual. Parts Information Parts are expected to be available September 13, 2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5259 Electrical Symbols Part 7 Page 9291 Electrical Symbols Part 1 Page 5147 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5600 Conversion - English/Metric Brake Hose Replacement Brake Hose/Line: Service and Repair Brake Hose Replacement Front Brake Hose Replacement - Front Page 14979 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 7999 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 14505 Position Sensor - Rear Motor (W/Memory Seat) Page 9488 C308 C309 (Long Wheelbase Body,Type VIN 6) Part 1 Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 5094 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 2371 Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Page 4628 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9934 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Page 3130 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 14465 1. Install the mid-position floor latch assembly to the seat cushion frame with the bolts (1). Tighten Tighten the rear seat mid-position floor latch assembly bolts to 35 N.m (26 lb ft). 2. Install the cable (3) to the mid-position floor latch assembly (2). 3. Install the rear center seat belt buckle assembly to the floor latch assembly. 4. Install the trim panel to the seat cushion. 5. Install the seat in the vehicle. Seat Latch Rod Replacement - Rear No. 2 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). Page 14118 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10688 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, RH REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the floor air outlet duct retaining screws (2,3,4). 3. Remove the RH side floor air outlet duct (1). INSTALLATION PROCEDURE 1. Install the floor air outlet duct (1) into position. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the floor air outlet duct retaining screws (2, 3, 4). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the HVAC module assembly. Page 6017 Electrical Symbols Part 1 Page 1669 Various symbols are used in order to describe different service operations. Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 14776 Electrical Symbols Part 5 A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 6257 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11822 Page 43 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 10123 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7095 For vehicles repaired under warranty, use the table. Disclaimer A/T - Transmission Mount Availability Transmission Mount: Technical Service Bulletins A/T - Transmission Mount Availability Bulletin No.: 04-07-30-035 Date: August 11, 2004 INFORMATION Subject: Release of Rear Transmission Mount Separate From Exhaust Mount Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) The purpose of this service bulletin is to announce the availability of the rear transmission mount without the exhaust mount bracket included. Previously when ordering the rear transmission mount from GMSPO, it could only be ordered with the exhaust mount bracket included. Currently, you can order the rear transmission mount without the exhaust mount bracket from GMSPO. When service requires the replacement of only the rear transmission mount and not the exhaust mount, order P/N 89040449 (2WD) and P/N 89040448 (4WD). Page 11429 Page 14279 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Page 1029 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting the windshield wiper module, installing a breathable seal to the vent on the wiper motor cover if applicable, or if necessary, installing a new windshield wiper module. INSPECTION PROCEDURE 1. Using a flashlight, look down through the air inlet screen (1) at the location shown. ^ If the color of the can (2) on the wiper motor is SILVER, no repairs are required on the vehicle. ^ If the color of the can (2) on the wiper motor is BLACK, proceed to the section below titled, REPAIR PROCEDURE. REPAIR PROCEDURE 1. Verify that all of the functions of the wiper system (low, high, delay, etc.) operate properly. 2. Turn the key to the OFF position. 3. Open the hood. Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J43631 Ball Joint Remover Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the wheel hub and bearing. 6. Remove the outer tie rod retaining nut. Page 14304 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear No. 1 Trailblazer, Envoy, and Bravada REMOVAL PROCEDURE 1. Remove the seat back cover and pad. 2. Remove the latch release assembly. 3. Remove the head restraint retractor assembly. 4. Remove the seat back hinge brackets. 5. Remove the seat belt retractor assembly, on the left side only. 6. Remove the latch release cable (1), and the head rest restraint cable (2) from the left-hand hinge bracket. 7. Remove the latch release cables from the right-hand hinge bracket. INSTALLATION PROCEDURE Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 3444 Water Pump: Service and Repair Water Pump Replacement ^ Tool Required J 41240 Fan Clutch Wrench Removal Procedure 1. Drain the coolant. 2. Remove the fan and shroud. 3. Remove the drive belt. 4. Using the J41240, secure the water pump pulley and remove the water pump pulley bolts. 5. Remove the J41240. 6. Remove the water pump pulley. 7. Loosen and remove the water pump bolts. 8. Remove the water pump. 9. Clean and inspect the water pump. 10. Discard and replace the gasket. Installation Procedure Page 12159 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10372 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Page 4130 Electrical Symbols Part 1 Diagrams Seat Heater Sensor: Diagrams Heated Seat Element - Driver Cushion Heated Seat Element And Thermistor Assembly - Driver Back Page 742 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12533 Page 8889 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear brake caliper on the mounting bracket. ^ Tighten the brake caliper mounting bolts to 31 Nm (23 ft. lbs.). 6. Install the NEW metal (copper) gaskets on the brake hose bolt. 7. Remove the plug from the brake hose end. 8. Install the brake hose bolt on the rear brake caliper. ^ Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting Page 12497 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 12603 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 5629 Page 11173 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 10151 The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 2. Turn the steering wheel so that the front wheels are pointing straight ahead. 3. Turn the ignition switch to the lock position and remove the key. 4. Lock the steering column through the access hole in the lower steering column trim cover using the J 42640. 5. Raise and support the vehicle. 6. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 7. Remove the lower intermediate shaft to upper intermediate shaft pinch bolt. 8. Disconnect the lower intermediate shaft from the upper intermediate shaft. 9. Lower the vehicle 10. Attempt to duplicate the customer's concern again. ^ If the noise is still present with the intermediate shaft disconnected, DO NOT replace the intermediate shaft. ^ If the noise is not present, continue with the next step. 11. Raise and support the vehicle. Page 7458 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). Page 10466 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 12065 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2946 First and second design balancers hubs are shown to assist the technician with proper identification of parts. First design balancers that need to be replaced should be replaced with the second design balancer and the appropriate seal. Parts Information Parts are currently from GMSPO. Disclaimer Page 10666 6. Remove the HVAC B fuse for a minimum of 10 seconds. 7. Re-install the HVAC B fuse. 8. Place the ignition switch in the RUN position. 9. Wait 40 seconds for the auxiliary HVAC control module to re-calibrate. 10. Verify that no DTCs have set as current DTCs. Re-Calibrating Actuators (Primary) When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a re-calibration process. When installing the HVAC control module be sure to perform the following: 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the HVAC control module. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. Wait 40 seconds for the HVAC control module to re-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing the motor assembly it will be necessary to allow the HVAC control module to perform a re-calibration process. When installing the motor assembly be sure to perform one of the following: Preferred Method (W/Scan Tool) 1. Clear all DTCs 2. Place the ignition switch in the OFF position. 3. Install the motor assembly. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. With the scan tool, initiate the Motor Re-calibration feature of the HVAC module Special Functions menu. 7. Verify that no DTCs have set as current DTCs. Alternate Method (W/O Scan Tool) 1. Clear all DTCs 2. Place the ignition switch to the OFF position. 3. Disconnect the scan tool. 4. Install the motor assembly. 5. Re-connect all previously disconnected components. 6. Remove the HVAC B fuse for a minimum of 10 seconds. 7. Re-install the HVAC B fuse. 8. Place the ignition switch in the RUN position. 9. Wait 40 seconds for the HVAC control module to re-calibrate. 10. Verify that no DTCs have set as current DTCs. Recirculation Actuator REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the air inlet assembly screws. 3. Remove the air inlet assembly. Page 8010 4. Remove the left hand heat, vent and air conditioning vent. 5. Remove the three electrical connectors from the transfer case control module. 6. Remove the transfer case control module. Important: When removing the transfer control module, it is not uncommon for the mounting bracket to be removed at the same time the transfer case control module is removed. 7. Remove the transfer case control module from the mounting bracket. Installation Procedure Important: The following service procedure is more easily performed if the mounting bracket and the electrical connectors are installed on the transfer case module before installing the transfer case module to the central support bracket. Page 4788 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Locations Locations View Page 14305 1. Install the latch release cable to the right-hand hinge bracket. 2. Install the seat belt retractor assembly, on the left side only. 3. Install the seat back hinge brackets. 4. Install the head restraint retractor assembly. 5. Install the latch release assembly. 6. Install the latch release cables (1) and the head rest restraint cable (2) to the left-hand hinge bracket. 7. Install the seat back cover and pad. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE Specifications Transmission Speed Sensor: Specifications Speed Sensor Retainer Bolt ..................................................................................................................................................... 10.5-13.5 Nm (7.7-10 ft. lbs.) Page 9939 Alignment: Service and Repair Wheel Alignment Measuring Procedures Inspection and Preparation Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Irregular or premature wear ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Alignment Angle Measurement Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Page 7994 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 5493 Fuel Injector Coil Test - Steps 1-7 The numbers below refer to the step numbers on the diagnostic table. 3. This step tests each fuel injector resistance within a specific temperature range. If any of the fuel injectors display a resistance outside of the specified value, replace the fuel injector. 4. This step determines if all of the fuel injectors are within 3 ohms of each other. If the highest resistance value is within 3 ohms of the lowest resistance value, then all of the fuel injector coil windings are OK. 5. This step determines which fuel injector is faulty. After subtracting the highest and lowest resistance values from the average value, replace the fuel injector that has the greatest resistance difference from the average. Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 2042 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 10577 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J43631. Installation Procedure 1. Install the stud into the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rotor. 6. Install the tire and wheel. 7. Lower the vehicle. Page 12353 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 1312 Electrical Symbols Part 7 Page 15896 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. A/C - Mode Door Actuator Tool Air Door Actuator / Motor: All Technical Service Bulletins A/C - Mode Door Actuator Tool Subject: Info - Essential Tool for HVAC Mode Door Actuator Replacement # 05-01-38-001A (04/08/2005) Models: 2002 Chevrolet TrailBlazer Models 2002 GMC Envoy Models 2002 Oldsmobile Bravada This bulletin is being revised to update the references to the service procedures in SI and add warranty and parts information. Please discard Corporate Bulletin Number 05-01-38-001 (Section 01 - HVAC). The purpose of this service bulletin is to announce the release of a new essential tool to service the Heating, Ventilation and Air Conditioning (HVAC) Mode Door Actuator. The new tool is an HVAC Puller, special tool number GE-47676, which was shipped in the Fall of 2004 to all Chevrolet and GMC dealers. It will no longer be necessary to replace the entire Mode Door Cam Assembly when only the Mode Door Actuator requires replacement. Previous to the release of this tool, it was necessary to remove the entire Instrument Panel Carrier to replace the Mode Door Cam Assembly. Now the Mode Door Actuator can be serviced from underneath the left side of the Instrument Panel Carrier using this new special tool. The service procedures in SI have been updated to include the use of this new special tool. To replace the entire Mode Door Cam Assembly refer to the Mode Cam Replacement procedure in SI for more information (Document ID # 1618104). To replace just the Mode Door Actuator, refer to the Mode Actuator Replacement procedure in SI for more information (Document ID # 1609154). The labor time associated with labor operation D1808 has been changed to reflect the time savings when this new special tool is used. Labor operation D1829 has been added to the labor time guide to be used if the entire Mode Door Cam Assembly is replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8973 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). 7. Install the boot seals into the caliper housing bores using the J 8092 and the J 43885. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions Page 15302 Electrical Symbols Part 4 Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Disconnect the crankcase dirty air hose from the intake manifold. 2. Disconnect the crankcase dirty air hose from the positive crankcase ventilation (PCV) orifice tube. 3. Loosen the throttle body clamps (2). 4. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator. Page 5145 Electrical Symbols Part 8 Page 15394 Electrical Symbols Part 3 Page 1965 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 9834 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 2281 4. Loosen the lower control arm adjustment bolts (1). 5. Adjust the caster and the camber angle by repositioning the lower control arm (2) until the specifications have been met. 6. When the adjustments are complete, hold the lower control arm in position so that the specifications do not change while tightening the lower control arm adjustment bolts. Tighten the lower control arm adjustment bolts to 160 Nm (118 ft. lbs.). 7. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment 1. Loosen the jam nut on the outer tie rod (2). Notice: Care must be taken that the boots are not: twisted when rotating the inner tie rods, or damage to the boots may result. 2. Rotate the inner tie rod (1) to the required toe specification setting. 3. Tighten the jam nut on the outer tie rod. Tighten the outer tie rod jam nut to 75 Nm (55 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5963 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 3672 Electrical Symbols Part 1 Page 12138 Speaker: Locations Locations View Page 11375 Disclaimer Page 9536 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 15490 Electrical Symbols Part 2 Page 14740 Audible Warning Device: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12105 Navigation Module: Service and Repair Trailblazer EXT, Envoy XL REMOVAL PROCEDURE 1. Fold and tumble the right rear seat to a cargo position. 2. Leaving the electrical connectors attached, remove the communication interface module from the Vehicle Communication Interface Module (VCIM) bracket. Refer to Communication Interface Module Replacement (Trailblazer, Envoy, Bravada) or Communication Interface Module Replacement (Trailblazer EXT, Envoy XL) in Interior Trim. 3. Using a flat bladed tool, release the retaining tab (1) on the VCIM bracket. 4. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 5. Remove the VCIM bracket from vehicle. 6. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 7. Remove the VCIM bracket from vehicle. INSTALLATION PROCEDURE Page 10782 Blower Motor Switch: Service and Repair HVAC Systems - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 13631 1. Position the garnish molding (1) to the vehicle. 2. Align the locating fingers to the corresponding holes in first pillar. 3. Starting at the top of the garnish molding, seat the attachment clips that retain the garnish molding to the first pillar. Rear Quarter Upper Trim Panel Replacement REMOVAL PROCEDURE 1. Remove the cargo shade/cover. 2. Remove the screw that retains the trim panel to the body. 3. Remove the cargo net retaining knobs. 4. Remove the bolt that retains the seat belt upper guide to the body. 5. Remove the rear upper quarter trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the rear upper quarter trim panel to the vehicle. 2. Install the seat belt retractor to the body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the rear seat belt upper guide to the body. Tighten Tighten the rear seat belt upper guide shoulder bolt to 70 N.m (52 lb ft). 4. Install the screw that retains the rear upper quarter trim panel to the body. Tighten Page 1478 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 14364 15. Release the 3 hog-rings from the reinforcement bar. 16. Remove the seat cover from the pad. INSTALLATION PROCEDURE 1. Install the seat back pad to the seat back frame. 2. Install the 6 push pins that retain the seat back pad to the seat back frame. 3. Partially install the seat cover. 4. Install the 3 hog-rings to the reinforcement bar. Page 15987 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 3233 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5023 Electrical Symbols Part 2 Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 14382 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Front REMOVAL PROCEDURE 1. Adjust lumbar to a relaxed position. 2. Remove the front seat assembly from the vehicle. 3. Remove the seat pad trim panel. 4. Remove the head restraint. 5. Remove the screw that retains the seat belt bezel to the top of the seat back. 6. Release the J-strips (1, 4) across the bottom of the seat back cover. 7. Remove the push pins (3) securing the seat cover (2) to the seat frame. 8. Release the J-strips (1, 4) across the bottom of the seat back cover. Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Assembly to Case Bolt ......................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Page 15543 Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Page 4002 Electrical Symbols Part 6 Page 5487 Fuel Injector: Connector Views Fuel Injector 1 Fuel Injector 2 Page 12678 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 4897 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 57 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 12905 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill only through the hinge base (1). Do not drill through the mating surface (2). 6. At each punch location, drill a 3-mm (1/8-in) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19-mm (3/4-in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 10347 Air Spring: Service and Repair Air Spring Replacement Air Spring Replacement Removal Procedure Caution: A sudden release of pressure may cause personal injury or damage to the vehicle. The air suspension system is under pressure until the air supply lines are disconnected. Use the following precautions when servicing the air suspension system: ^ Wear gloves, ear protection, and eye protection. ^ Wrap a clean cloth around the air supply lines. Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Raise and support the rear axle at the designed D-height. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D- Height and Full Jounce. 4. Depressurize the air suspension system. Important: There is a raised feature on the outer rim of the air spring top plate that denotes the anti rotation peg position. 5. Depress the antirotation peg (2) in the air spring top plate located in the upper spring seat. 6. With the anti rotation peg (2) depressed, rotate the air spring counterclockwise and remove the air spring from the upper spring seat. 7. Disconnect the air supply line from the air spring in the following way: ^ Push the air supply line into the air spring connection and hold in place. ^ Depress and hold the air supply line collet (2) down. ^ Remove the air supply line (1) from the air spring. Body - Door(s) Are Difficult To Close Rear Door Striker: Customer Interest Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 5459 Electrical Symbols Part 7 Page 11948 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 5006 IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2(TM), select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Page 3922 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 9685 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 7750 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11651 Document ID # 162420). 8. Install an anti-abrasion sleeve, P/N 15166433, around both harnesses in the contact area and install a tie-strap, P/N 12337820 or equivalent, around the anti-abrasion sleeve as shown. 9. Position the trim panel to the IP. 10. Seat the clips that retain the trim panel to the IP. 11. Install the four trim panel retaining screws. Tighten Tighten the screws to 2.5 Nm (22 lb in). 12. Position the insulator panel to the IP. 13. Install the two screws that retain the insulator panel to the IP. Tighten Tighten the screws to 2.5 Nm (22 lb in). Parts Information Parts are expected to be available 1-18-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. Steering - Steering Gear Stub Shaft Bearing Kit Steering Gear: Technical Service Bulletins Steering - Steering Gear Stub Shaft Bearing Kit INFORMATION Bulletin No.: 04-02-32-001F Date: December 02, 2009 Subject: Release of Steering Gear Stub Shaft Bearing Kit for Service Models: 2002-2005 Buick Century, LeSabre, Park Avenue, Regal 2002-2007 Buick Rendezvous 2004-2007 Buick Rainier 2005-2007 Buick Buick Allure (Canada), LaCrosse, Terraza 2002-2005 Chevrolet Cavalier, Impala, Malibu Classic, Venture 2002-2007 Chevrolet Monte Carlo 2002-2009 Chevrolet TrailBlazer 2003-2010 Chevrolet Express 2004-2007 Chevrolet Silverado (2WD) (Classic) 1500 Series 2005-2009 Chevrolet Uplander 2002-2009 GMC Envoy Models 2003-2007 GMC Sierra (2WD) (Classic) 1500 Series 2003-2010 GMC Savana 2002-2003 Oldsmobile Bravada 2002-2004 Oldsmobile Alero, Silhouette 2002-2004 Pontiac Aztek 2002-2005 Pontiac Bonneville, Grand Am, Montana, Sunfire 2002-2008 Pontiac Grand Prix (Excluding GTP Models) 2005-2009 Pontiac Montana SV6 2005-2007 Saturn RELAY 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the information. Please discard Corporate Bulletin Number 04-02-32-001E (Section 02 - Steering). GMSPO has released a steering gear stub shaft bearing kit, P/N 26032824, for service on the above-mentioned vehicles. For detailed usage, refer to Group Number 06 (Front Suspension-Steering) of the GM Parts Catalog. Previously, to correct a pinion seal leak or squeak, the steering gear assembly had to be replaced because the pinion stub shaft bearing, seal and seal retainer were not serviceable. Technicians may now order the kit instead of replacing the steering gear assembly. Disclaimer Page 13538 Air Bag(s) Arming and Disarming: Service Precautions Inflator Module Handling, Storage, Deploying and Storing Precautions SIR CAUTIONS Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: ^ Air bag deployment ^ Personal injury ^ Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: ^ Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. ^ If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Air Bag(s) Arming and Disarming. SIR Deployed Inflator Modules Are Hot Caution: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury: ^ Allow sufficient time for cooling before touching any metal surface of the inflator module. ^ Do not place the deployed inflator module near any flammable objects. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Inflatable Module Deployment Outside Vehicle Caution: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result In personal injury. SIR Inflator Module Disposal Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. SIR Inflator Module Handling and Storage Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tools Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified and the instructions provided. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Locations Locations View Page 6779 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 6473 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5955 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 2498 Fluid - Transfer Case: Fluid Type Specifications Transfer Case ............................................................................................................................................................. AutoTrak II Fluid GM P/N 12378508 Page 1032 20. Remove the backing material from the seal, align it over the wiper motor cover so that it completely covers the vent (2), and press it firmly into place as shown in the above illustration. Apply firm pressure across the entire surface of the seal and around all outside edges. Continue applying pressure a second time to the edges to assure full adhesion. 21. Position the wiper module to the vehicle and connect the electrical connector. 22. Install the wiper module in the plenum sheet metal. 23. Install the two 10 mm hex head bolts that attach the module to the plenum sheet metal. Tighten Tighten the bolts to 8 N.m (71 lb in). 24. Install the air inlet grille to the plenum sheet metal. 25. Install the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. Tighten Tighten the nuts to 4 N.m (35 lb in). 26. Install the antenna mast. Important If installing a NEW wiper module, you must verify that the new wiper motor and transmissions are in the PARK position before installing the wiper arms. 27. If installing a NEW wiper module, turn the ignition switch to the ON position, turn the wiper switch ON, and visually verify that the wiper transmissions operate. After visually verifying operation, turn the wiper switch to the OFF position and allow the wiper transmissions to stop moving before turning the ignition switch to the OFF position. The wiper motor will now be in the PARK position. 28. Using the marks or masking tape that were placed on the windshield, align and position the wiper arms on the wiper transmission shafts. 29. Install the nuts on the wiper transmission shafts. Tighten Tighten the nuts to 30 N.m (22 lb ft). 30. Install the covers on the wiper arm nuts. 31. Remove the marks or masking tape from the windshield. 32. Open the hood. 33. Install the three push-in retainers that attach the air inlet grille to the plenum sheet metal. 34. Close the hood. 35. Verify that all functions of the wiper system (low, high, delay, etc.) operate properly. Page 5583 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4547 INSTALLATION PROCEDURE IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. Service and Repair Power Mirror Switch: Service and Repair REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 8305 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1931 For vehicles repaired under warranty, use the table. Disclaimer Body - Door Mirror Actuator Replacement Power Mirror Motor: Technical Service Bulletins Body - Door Mirror Actuator Replacement Info - Availability of Replacement Mirror Actuator # 03-08-64-033 (09/11/2003) Availability of Replacement Mirror Actuator Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2003 Oldsmobile Bravada A replacement mirror actuator is available for service. It is no longer necessary to replace the mirror assembly for an actuator. Use the following procedure to replace the actuator. 1. Rotate the mirror into the upward and outboard position. See the illustration above. 2. Position your fingers flat and insert them underneath the raised corner. This will ensure that more surface of the mirror is used when removing the glass. See the illustration above. 3. Slowly but firmly lift the glass and backing plate from the actuator. 4. Remove the wire harness from the glass if equipped with heated mirror and turn signal. 5. Remove the glass. 6. Remove the three torque head screws from the actuator. 7. Remove the actuator. 8. Remove the wire harness from the actuator. 9. Install the wire harness to the new actuator. 10. Install the new actuator. Page 9302 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 1718 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3003 2. Install the valve spring and the valve spring retainer. 3. Use the J 44228 and compress the valve springs. 4. Install the valve keys. 5. Remove the J 44228. Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Locations Locations View Engine Controls - SES Lamp ON/DTC P0135 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 14357 9. Using a flat-bladed tool, carefully disengage the plastic strips that retain the seat back cover to the side airbag inflator module cover. 10. Carefully remove the seat back cover from behind the trim edge of the side airbag inflator module. 11. Compress the seat back pad in order to relieve the pressure against the seat cover. 12. Using a side to side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. IMPORTANT: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the pad. 13. Release the lower Velcro retaining strips located inside the seat cover. 14. Remove the 3 hog rings that retain the seat back pad to the reinforcement bar located at the top of the seat back. Locations Locations View - HVAC Systems - Automatic Page 273 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 13484 14. Install the lift gate door sill plate. 15. Install the rear door sill plates. 16. Install the front door sill plates. 17. Install the front bucket seats. 18. Install the seat back, right and left side. 19. Install the navigation control processor bracket to the floor panel. 20. Install the rear seat cushions. 21. Install the communication interface module. 22. Install the front seats. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the front seats. 2. Remove the second row rear seats. 3. Remove the third row rear seats. 4. Remove the front door sill plates. 5. Remove the rear door sill plates. NOTE: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 6. Remove the center pillar trim panels. 7. Remove the lift gate door sill plate. 8. Remove the left/right front body side window garnish molding. 9. Remove the left/right rear body side window garnish molding. 10. Remove the bolts from the cargo tie-down loops. 11. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 12. Loosen the three bolts that secure the jack carrier to the vehicle. 13. Remove the carpet from around the wheel stud. 14. Remove the body electrical block. 15. Remove the body electrical block electrical connectors back through the hole in the carpet. 16. Pull the communication interface module electrical connectors back through the hole in the carpet. Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 4014 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 4952 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14478 3. Install the SIR harness to the harness clips (2) on the seat adjuster. 4. Install the SIR harness connector (1) to the seat adjuster bracket. 5. Install the seat belt buckle to the seat adjuster. Tighten Tighten the seat belt buckle nut to 55 N.m (41 lb ft). 6. Install the lumbar support cable to the seat adjuster. 7. Install the seat cushion trim panel. 8. Install the front bucket seat assembly to the vehicle. Page 734 Electrical Symbols Part 2 Page 10646 door to the desired position. Defrost Actuator The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position. Front Defrost When defrost is selected, the A/C compressor is activated. The A/C compressor clutch will engage when ambient temperatures are above 3°C (38°F). The blower motor will be activated, regardless of the coolant temperature. The HVAC control module will override the auxiliary HVAC control module so a high volume of air is delivered to the front defrost vents. The rear window defogger does not affect the HVAC system. Trailblazer, Envoy, and Bravada The auxiliary HVAC system provides ventilation for the rear seat occupants. The rear seat occupants will exercise control of the auxiliary air delivery modes and air speed, while the HVAC control module will maintain control of the air temperature setting. The HVAC control modules blower motor must be ON in order for the auxiliary HVAC system to receive heated or cooled air. The HVAC control module will have the authority to override the auxiliary HVAC system and place it in the OFF mode when a high volume of front defrost air is required. To override the auxiliary HVAC control module, a signal is delivered from the HVAC control module through the class 2 serial data circuit, to the auxiliary HVAC control module. This pause in operation will be indicated by the flashing the text OFF. When the auxiliary mode switch is toggled, a signal is sent to the auxiliary mode actuator through the auxiliary mode door control circuit. Power and ground are supplied to the auxiliary mode actuator through the ignition 3 voltage and ground circuits. When the HVAC control module is ON, the air that is delivered to the auxiliary HVAC system is the low auxiliary blower speed. When the operator selects medium blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor medium speed control circuit. When the operator selects high blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor high speed control circuit. Ground is provided to the blower motor through the ground circuit. Power and ground are provided to the auxiliary HVAC control module through the ignition 3 voltage and ground circuits. TrailBlazer EXT, and Envoy XL The auxiliary HVAC system provides ventilation for the rear seat occupants. The auxiliary mode actuator shares a control circuit with the auxiliary air temperature actuator. If change of position is required for both actuators, then the module positions the auxiliary air temperature actuator first. All control circuits for the auxiliary actuators are at a low voltage potential until a change of position is required. The module then applies a high voltage potential to the appropriate control circuit, which will rotate the actuator. Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 4686 Locations View Page 3945 Electrical Symbols Part 2 Page 3022 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Page 6256 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 5499 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis CIRCUIT DESCRIPTION The powertrain control module (PCM) enables the appropriate fuel injector on the intake stroke for each cylinder. A voltage is supplied directly to the fuel injectors. The PCM controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS ^ Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help isolate an intermittent condition. ^ Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics ^ For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Fuel Injector Circuit Diagnosis - Steps 1-8 The numbers below refer to the step numbers on the diagnostic table. 3. This step tests for an open ignition 1 voltage supply circuit between the PCM 1 fuse and the multi-way connector. 4. This step tests for an open or high resistance between the multi-way connector and the fuel injectors. Page 5379 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis REMOVAL PROCEDURE 1. Remove the fuel bundle. 2. Remove the evaporative emission (EVAP) purge pipe (3) from the fuel bundle. INSTALLATION PROCEDURE 1. Place the new EVAP purge pipe (3) in the fuel bundle. 2. Install the fuel bundle. Page 15785 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 11923 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 14081 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With the aid of an assistant, remove the sunroof assembly from the vehicle and place on a clean, prepared surface. Refer to Sunroof Replacement 4. Remove the sunroof drive motor. 5. Remove the screw that retains the module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the module. 7. Remove the module from the mounting bracket. INSTALLATION PROCEDURE IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 1. Position the module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw that retains the module to the mounting bracket. Tighten Page 10955 Heater Control Valve: Diagrams Coolant Bypass Valve (Body Type VIN 6) - HVAC Systems - Manual Coolant Bypass Valve (Body Type VIN 6) - HVAC Systems - Automatic Page 1864 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Rear Door Window Belt Outer Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten Tighten the screw to 1.2 N.m (10 lb in). Page 8998 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Support the vehicle with safety stands. 3. Clean the din and foreign material from the brake hose and brake pipe fitting. 4. Install a rubber cap or plug on the brake pipe fitting in order to prevent brake fluid loss and contamination. 5. Using a backup wrench disconnect the brake hose and brake pipe fitting 6. Remove the brake hose retainer. 7. Remove the brake pipe from the brake junction block. 8. Remove the brake junction block mounting bolt. 9. Remove the brake hose. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. Important: After installation, ensure that the rear flex hose is not twisted and that the rear flex hose does not come in contact with any other components. 1. Install the brake junction block mounting bolt. Tighten Tighten the brake junction block bolt to 17 Nm (13 lb ft). 2. Install the brake hose to the brake junction block. Tighten Tighten the brake hose fitting to 17 N.m (13 lb ft). 3. Install the brake hose fitting to the brake pipe fitting. Tighten Tighten the brake hose fitting to 17 N.m 13 lb ft). 4. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. 5. Remove the safety stands 6. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Page 4795 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 7949 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 698 INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. Page 5771 Electrical Symbols Part 5 Page 4631 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 1317 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Blower Motor Resistor Assembly Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement REMOVAL PROCEDURE 1. Remove the right closeout/Insulator panel. 2. Disconnect the blower motor resistor electrical connector (3). 3. Remove the blower motor resistor mounting screws (2). 4. Remove the blower motor resistor (1). INSTALLATION PROCEDURE 1. Install the blower motor resistor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor mounting screws (2). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the blower motor resistor electrical connector (3). 4. Install the right closeout/Insulator panel. Page 5797 Equivalents - Decimal And Metric Part 1 Page 15671 Center Mounted Brake Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 4422 Various symbols are used in order to describe different service operations. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 6637 Disclaimer Page 8193 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4568 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8609 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Memory Seat Switch Replacement REMOVAL PROCEDURE Page 2342 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Page 13010 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 6711 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Description and Operation Traction Control Indicator Lamp: Description and Operation Traction Control Indicators (w/NW7) LOW TRACTION The low traction indicator is part of the traction control switch. The EBCM applies ground to the traction control active signal circuit in order to illuminate the low traction indicator during a traction control event. TRACTION OFF The traction off indicator, which is part of the traction control switch, turns OFF when ground is applied to the service traction control signal circuit. The EBCM illuminates the traction off indicator if any of the following conditions are present. ^ The EBCM inhibits the traction control system. ^ The driver manually disables the traction control system by pressing the traction control switch. ^ The automatic transmission shift lever is in the low (1) position. The EBCM inhibits the traction control system when a TCS-disabling malfunction occurs, or when the automatic engagement feature is programmed to disable the TCS when the ignition is turned ON. Refer to Programming the Traction Control Automatic Engagement Feature. Page 2360 Disclaimer Page 13732 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 11729 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 10481 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 3376 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3984 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft position (CMP) sensor. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 271 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 8497 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 11975 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 2441 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TrailBlazer, Envoy, and Bravada TOOLS REQUIRED ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Loosen the evaporator tube (6) from the evaporator. 3. Remove the evaporator tube nut from the condenser. 4. Remove the nuts (1,5) retaining the evaporator tube to the fender. 5. Remove the washer solvent container. 6. Remove the coolant recovery tank. 7. Remove the evaporator tube using J 26549-E. 8. Remove the O-ring seal and discard. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the evaporator tube. Connect the evaporator tube to the evaporator. Page 11194 Solar Sensor: Description and Operation SUNLOAD SENSOR The sunload sensor is a 2 wire photo diode. The vehicle uses left and right sunload sensors. The two sensors are integrated into the sunload sensor assembly. Low reference and signal circuits enable the sensor to operate. As the light shining upon the sensor gets brighter, the sensor resistance increases. The sensor signal decreases as the resistance increases. The sensor operates within an intensity range between completely dark and bright. The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between 0-255 counts. The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted sunload value. This value will not be displayed on the scan tool. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is fixed. The scan tool parameter for the sunload sensor is the actual state of the signal circuit. Page 749 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15696 Conversion - English/Metric Luggage Carrier - Windnoise Roof Rack Frame: All Technical Service Bulletins Luggage Carrier - Windnoise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-58-004 Date: September, 2001 TECHNICAL Subject: Windnoise or Gap Between Luggage Carrier Side Rail Front Cover and Roof Sheet Metal (Secure Front Side Rail Corners and/or Reposition Cross Bows) Models: 2002 Chevrolet and GMC SIT Utility Models (Trail Blazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment about wind noise coming from the roof or luggage carrier area when driving at highway speeds. Also comments may be received about a gap between the luggage carrier side rail front cover(s) and the roof sheet metal. Cause One or both of the following may cause the conditions: Cause # 1 The bolt attaching the luggage carrier side rail front corner (1) may be over tightened, causing the mounting surface to lift up leaving a gap (3) between it and the roof sheet metal (2). This can occur on either the left or right side rail front corner. Cause # 2 The luggage carrier front (2) and rear cross bows (1) are not positioned correctly when not in use. Correction Correction # 1 Page 3174 Engine Oil Pressure (EOP) Switch Page 5469 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 9038 12. Remove the park brake retaining bracket bolt from the frame. 13. Remove the park brake retainer from the frame, left rear shown. 14. Depress the retaining clips for the parking brake cable. 15. Remove the park brake from the mounting bracket. 16. Remove the park brake cable from the actuator. 17. Push the park brake cable through the frame toward the inside from the vehicle. 18. Remove the park brake cables from the vehicle. Installation Procedure Page 5586 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 7652 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 14302 10. Remove the SIR wiring harness (1) from the seat back frame. 11. Remove the lumbar wiring harness (3) from the seat back frame. 12. Remove the wiring harness clips (2) from the seat back frame. INSTALLATION PROCEDURE 1. Install the wiring harness clips (2) to the seat back frame. 2. Install the lumbar wiring harness (3) to the seat back frame. 3. Install the SIR wiring harness (1) to the seat back frame. Specifications Slip Yoke: Specifications Propeller Shaft Yoke Retainer Bolts ......................................................................................................................................................... 20 Nm (15 ft. lbs.) Page 12911 10. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location (4) on the door according to the service hinge. 3. Drill a 3-mm (1/8-in) pilot hole at each location (1). 4. Drill a 13-mm (1/2-in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 5827 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Audio Amplifier, Short Wheelbase Locations View Page 7161 11. Using J2845fl release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 2947 Harmonic Balancer - Crankshaft Pulley: Technical Service Bulletins Engine - Revised Harmonic Balancer File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-012 Date: April, 2002 INFORMATION Subject: Revised Harmonic Balancer Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Built After VIN Breakpoint 22358862 A new second design Harmonic Balancer is being used on the 4.2L engine. The new second design may be used to replace the previous first design. All first design balancers should be removed using the J 44226 removal tool. The second design balancer should be removed with a standard three jaw puller. Refer to the Engine Mechanical sub-section of the appropriate Service Manual for complete removal and installation procedures. The illustration shows the first and second design parts. Parts Information The part numbers have been changed as well. GMSPO has cancelled and replaced the first design part number with the second design part number. Parts are currently available from GMSPO. Page 4860 Electrical Symbols Part 4 Page 15903 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 8181 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 7862 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer Ext, Envoy XL) Transfer Case Motor/Encoder Replacement (Trailblazer EXT, Envoy XL) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/Encoder is in the neutral position. 1. Raise the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the motor/encoder electrical connector. 4. Remove the motor/encoder mounting bolts. 5. Remove the motor/encoder assembly. Installation Procedure OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 10549 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Tools Required ^ J8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J8001 to a stand. 3. Ensure that the J8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Page 6219 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 6126 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 11365 Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the left rear quarter trim panel. 4. Install the rear seat belt floor anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt floor anchor bolt to 70 N.m (52 lb ft). 5. Install the lower seat belt anchor bolt cover. 6. install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt upper guide bolt to 70 N.m (52 lb ft). Child Seat Refer to Child Seat Tether Attachment. See: Child Restraint/Child Seat Tether Attachment Page 12623 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14986 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 12528 Page 15310 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8896 9. Remove the outboard brake pad. 10. Remove the inboard brake pad. 11. Remove the brake pad retaining clips from the brake caliper mounting bracket. Page 5246 2. Install the heated oxygen sensor (2). Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 4127 Locations View Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 6029 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 6103 Electrical Symbols Part 7 Page 5677 Electrical Symbols Part 7 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 12225 Page 4637 Equivalents - Decimal And Metric Part 1 Page 5930 Electrical Symbols Part 4 Page 9968 7. Disconnect the outer tie rod from the steering knuckle using J24319-B. 8. Remove the brake hose bracket retaining bolts. 9. Remove the brake hose bracket from the steering knuckle. 10. Remove the upper control arm to the steering knuckle pinch bolt and nut. 11. Disconnect the upper control arm from the steering knuckle. Page 11981 Page 13298 Body Emblem: Service and Repair Emblem Replacement - Grille Removal Procedure 1. Remove the grille. 2. Place the grille on a clean, prepared surface. 3. Remove the emblem retaining nuts. 4. Remove the emblem from the grille. Installation Procedure 1. Install the emblem to the grille. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the emblem to the grille. Tighten the nuts to 3 N.m (27 lb in). 3. Install the grille. Page 11962 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 12084 Special Tools And Equipment Page 13308 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9206 Electrical Symbols Part 1 Page 12434 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 2055 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 1658 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 10583 Accumulator HVAC: Service and Repair TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Disconnect the electrical connector from the A/C pressure switch. 3. Remove the A/C low pressure switch. 4. Remove the nut (3) retaining the accumulator (4) to evaporator (1). 5. Remove the compressor suction hose assembly from the accumulator. 6. Remove and discard the O-ring seals. 7. Remove the accumulator clamp nut. 8. Remove the accumulator from the vehicle. INSTALLATION PROCEDURE IMPORTANT: If replacing the accumulator, add the refrigerant oil to the accumulator. Refer to Refrigerant System Capacities (fan) refrigerant system capacities for the capacity information. 1. Install the accumulator to the vehicle. 2. Install the accumulator into the accumulator clamp. NOTE: Refer to Fastener Notice in Service Precautions. Page 4776 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1286 Door Switch: Diagrams Driver Miniwedge (Door Jamb Switch) - Driver Miniwedge (Door Jamb Switch) - Driver Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 1626 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) 1 Heated Oxygen Sensor (HO2S) 2 Locations Locations View Page 14993 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 8743 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9237 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: Customer Interest Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 2212 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Electrical - No Start/Multiple Systems Inoperative Audible Warning Device: All Technical Service Bulletins Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Locations Locations View Page 11005 Housing Assembly HVAC: Service and Repair HVAC Module Pass Thru Seal - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the HVAC Module-Auxiliary 2. Remove the screws from the heater core cover-auxiliary. 3. Remove the heater core cover-auxiliary 4. Remove the HVAC pass thru seal (3) from the HVAC module-auxiliary (1). INSTALLATION PROCEDURE 1. Install the HVAC pass thru seal (3) to the HVAC module-auxiliary (1). 2. Install the heater core cover-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the heater core cover-auxiliary. Tighten Tighten the screws to 1.9 N.m (18 lb in). 4. Install the HVAC Module-Auxiliary. Page 4196 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 12433 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 1417 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5692 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1747 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 15692 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3430 Spark Plug: Service and Repair Spark Plug Replacement Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 10014 Power Steering Fluid Cooler: Service and Repair Power Steering Cooler Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering hose assembly from the power steering cooler. 4. Remove the power steering cooler mounting bolts. 5. Remove the power steering cooler from the radiator support. Installation Procedure Recall - Windshield Wiper Defect Technical Service Bulletin # 04005 Date: 040701 Recall - Windshield Wiper Defect File In Section: Product Recalls Bulletin No.: 04005 Date: July, 2004 PRODUCT SAFETY RECALL SUBJECT: WINDSHIELD WIPER OPERATION MODELS: 2002-2003 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2002-2003 GMC ENVOY, ENVOY XL 2002-2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles. Under certain conditions, water may seep into the windshield wiper module. If this were to happen, it could result in windshield wipers that will not turn on, cease operation while driving, fail to turn off, turn on by themselves, and/or continuous windshield washer pump operation. Improper operation of the windshield wiper system in a severe weather situation could reduce the driver's visibility, resulting in a possible vehicle crash without prior warning. CORRECTION Dealers are to inspect and seal the windshield wiper motor. In some cases, the windshield wiper module may require replacement. VEHICLES INVOLVED Involved are certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. Page 14932 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 14985 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8642 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Exhaust - Exhaust Noise/Leak Exhaust Manifold: Customer Interest Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 10270 3. Connect the ABS wheel speed sensor wiring harness to the upper control arm. 4. Connect the upper control arm to the steering knuckle 5. Install the upper ball joint to upper control arm pinch bolt and nut. Tighten the upper ball joint to upper control arm pinch bolt to 40 Nm (30 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Check the front wheel alignment. Lower Control Arm Replacement Lower Control Arm Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Page 5675 Electrical Symbols Part 5 Page 3173 Oil Pressure Sender: Specifications Oil Pressure Sensor 15 ft. lbs. Page 1594 Electrical Symbols Part 3 Page 297 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 5844 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 3809 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 9907 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 3201 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Remove the throttle body. 2. Remove the PCM. 3. Disconnect all harnesses from the engine harness bracket. 4. Remove the front differential vent hose from the bracket clip. 5. Remove the engine harness bracket bolt and remove the bracket. 6. Disconnect the MAP sensor electrical connector. 7. Disconnect the crankcase ventilation hose. 8. Disconnect the brake hose at the booster. Page 14424 Seat Cushion: Removal and Replacement Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1, 4), and remove the SIR harness from the seat. 8. Remove the seat harness from the seat pan. 9. Remove the seat memory module, if equipped. 10. Remove the seat cushion assembly. 11. Remove the seat cushion cover and pad from the seat frame. 12. Remove the wiring harness and connector clips, if you are replacing the frame. Installation Procedure 1. Install the wiring harness and connector clips, if you replaced the frame. 2. Install the seat memory module, if equipped. 3. Install the seat cushion cover and pad to the seat frame. Page 4716 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15898 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Front Passenger Door Switch: Diagrams Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Miniwedge (Door Jamb Switch) - Front Passenger Page 5267 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 1448 Electrical Symbols Part 2 Page 8721 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 1544 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 4194 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer C100 - C105 Multiple Junction Connector: Diagrams C100 - C105 C100 C100 Page 7714 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5578 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 801 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 14462 1. Remove the seat back cover and pad. 2. Remove the release latch by pinching the lower locking tabs together. 3. Remove the release cable from the release latch. INSTALLATION PROCEDURE 1. Install the release cable to the release latch. Page 7498 Flex Plate: Specifications Engine Flywheel Bolt First Pass 18 ft. lbs. Final Pass 50 degrees Page 13847 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 3654 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 10307 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 14684 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Trailblazer, Envoy, Bravada REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. IMPORTANT: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. Page 13014 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Page 6871 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Cylinder Pipe Assemblies/O-Ring Repl - Off Vehicle Steering Gear: Service and Repair Cylinder Pipe Assemblies/O-Ring Repl - Off Vehicle Steering Gear Cylinder Pipe Assemblies/O-Ring Seals Replacement - Off Vehicle Removal Procedure Important: Protect the boots from sharp tools and from the sharp edges of surrounding components. 1. Remove the TORX screw (1) from the cylinder line retaining plate (2) at the valve end. 2. Remove the cylinder line retaining plate (2). 3. Loosen both cylinder line nuts (3) on cylinder end of the gear assembly (1). 4. Remove both cylinder line assemblies (2) from the rack and pinion gear assembly (1). 5. Remove and discard the O-rings seals (4) from the valve end (5). Installation Procedure 1. Inspect the cylinder lines (1) for the following items: Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 5816 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15399 Electrical Symbols Part 8 Page 12621 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 15042 2. Turn the ignition switch to the ON position. 3. Turn the Tech 2 ON by pressing the power button. 4. Verify that the Tech 2 has been updated with software version 8.0 or newer by reviewing the information on the bottom of the screen. 5. If the Tech 2 has the correct software, press the enter button. If the Tech 2 does not have the correct software, update the Tech 2 software. 6. Select "Diagnostics" on the "Main Menu" screen. 7. Select the "2002" model year. 8. Select "LD Trk, MPV, Incomplete." 9. Select "Body" on the "System Selection Menu" screen. 10. Select the letter "S" (for two wheel drive vehicle) or "T" (for four wheel drive vehicle) on the "Vehicle Identification Product Line" screen. 11. Select the appropriate vehicle name plate (Bravada, Envoy, Envoy XL, TrailBlazer, TrailBlazer EXT). 12. Select the HVAC type. 13. Select "Instrument Panel Cluster." 14. Select "ID Information" (F4). 15. Select "Module Information 2" (F1). 16. Review the IPC software part number displayed on the Tech 2. 17. Press the "Exit" button on the Tech 2 as necessary until the "Main Menu" is displayed. 18. Select "Service Programming System." 19. Follow the on-screen instructions on the Tech 2 and in TIS 2000 for reprogramming the IPC. 20. After reprogramming is complete, turn the ignition switch to the OFF position and disconnect the Tech 2. 21. Turn the ignition switch to the ON position and verify proper IPC operation. 22. Install the GM Identification Label. Identification Label - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store. Ask for Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. Identification Label - For Canada Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen. Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP91 when ordering. Courtesy Transportation Page 5935 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 1483 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 6153 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Tie Rod End Replacement - Outer Tie Rod End: Service and Repair Tie Rod End Replacement - Outer Tie Rod End Replacement - Outer Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the outer tie rod retaining nut. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 4. Disconnect the outer tie rod from the steering knuckle using J24319-B. Page 2338 Spark Plug: Specifications Ignition System Specifications Page 13292 Trunk / Liftgate Weatherstrip: Service and Repair Lift Gate REMOVAL PROCEDURE 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. INSTALLATION PROCEDURE 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Page 703 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 6. Install the rear electrical center cover. 7. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 1655 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5027 Electrical Symbols Part 6 Page 15059 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 8977 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake hose bolt. 4. Install a plug in the front brake caliper hose in order to prevent excessive brake fluid loss and contamination. 5. Discard the metal/copper gaskets. DO NOT reuse them replace with NEW metal/copper gaskets. 6. Remove the front brake caliper mounting bolts. 7. Remove the front brake caliper from the mounting bracket. Installation Procedure Page 15708 Electrical Symbols Part 3 Page 4582 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 4199 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5868 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 13754 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. Page 6332 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 13541 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 5573 Electrical Symbols Part 7 Page 5921 2. Install the ignition coil retaining bolts (2). Tighten Tighten the ignition coil retaining bolts to 10 N.m (89 lb in). 3. Replace the ignition coil connectors (1). 4. Replace the resonator. 5. Install the resonator bolts (2). Tighten Tighten the resonator retaining bolts to 10 N.m (89 lb in). 6. Tighten the integral clamp holding the resonator to the engine. Tighten Tighten the integral clamp to 4 N.m (35 lb in). Page 10889 Control Module HVAC: Description and Operation BLOWER MOTOR CONTROL PROCESSOR The blower motor control processor controls the speed of the blower motor by increasing or decreasing the voltage drop on the ground side of the blower motor. The HVAC control module provides a low side pulse width modulated signal to the blower motor control processor over the blower motor speed control circuit. As the requested blower speed increases, the HVAC control module increases the amount of time that the speed signal is modulated to ground. As the requested blower speed decreases, the HVAC control module decreases the amount of time that the signal is modulated to ground. Page 739 Electrical Symbols Part 7 Page 2317 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Fuse Block - Rear Fuse Block: Diagrams Fuse Block - Rear Fuse Block - Rear C1 Part 1 Page 13448 There may be a lack of sealer under the "A" pillar reveal molding push nuts. Refer to the illustration above. Cause 4 The push-in retainers at the base of the auxiliary weatherstrip may not be seated fully. Refer to the illustration above. Cause 5 There may be a gap between the many pieces of sheet metal under the primary seal flange. If this is present, water may enter under the primary seal retainer and into the vehicle between the gaps in the sheet metal flange and end up under the carpet. Refer to the illustration above. Correction 1 Page 16007 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 13488 Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 1428 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 9019 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 15999 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13880 Disclaimer Technical Service Bulletin # 03-08-111-002G Date: 071221 Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. Page 3563 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement - Auxiliary 2. Remove the screws from heater core cover-auxiliary (3) from the HVAC module-auxiliary. 3. Remove the heater core cover-auxiliary (3). 4. Remove the HVAC module pass thru seal-auxiliary. Remove the heater core-auxiliary (2) from the HVAC module-auxiliary. INSTALLATION PROCEDURE Page 3023 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 2101 Disclaimer Page 1341 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8581 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 9760 connector/leads on the body harness by splicing in the service pigtail, P/N 15306403, using the procedure listed below. Passenger Door 1. Inspect the passenger door harness connector (9 wires) and terminals (inline to body harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors sub-section of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (9 wires) and terminals (inline to passenger door harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If there is evidence of corrosion, replace the mating connector/leads on the body harness by splicing in the service pigtail, P/N 88953131, using the procedure listed below. Service Pigtail Procedure 1. Remove the closeout/insulator panel. 2. Remove the door sill plate. 3. Pull back the carpet for access. 4. Remove the driver foot rest pad. 5. Release the harness to body clips. 6. Pull the existing body harness through the door jam and into the body. 7. Cut the existing harness and splice in the service pigtail. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 8. Feed the harness through the body and into the door jam. 9. Install the harness to body clips. 10. Install the driver foot rest pad. 11. Install the carpet in place. 12. Install the door sill plate. 13. Install the closeout/insulator panel. Specifications Oil Pump Drive Shaft: Specifications Oil Pump Drive Gear Outer Diameter Tolerance 2.893-2.891 inch Width 0.613-0.611 inch Oil Pump Driven Gear Outer Diameter Tolerance 3.428-3.426 inch Width 0.605-0.611 inch Lobe Inner Diameter - Maximum 0.469 inch Page 804 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12543 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 3640 Radiator Hose: Service and Repair Radiator Hose Replacement- Outlet Radiator Hose Replacement- Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. 2. Reposition the outlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the outlet radiator hose. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the lower radiator support shield, if equipped. 6. Reposition the outlet radiator hose clamp at the radiator using J 38185. 7. Remove the outlet radiator hose (1) from the radiator. Installation Procedure Page 3123 Electrical Symbols Part 2 Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Page 8527 Disclaimer Page 5057 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 3962 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 9125 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Page 15587 Electrical Symbols Part 3 Page 2160 Disclaimer Page 7279 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 13586 25. Reach underneath the carpet and install the 6-way headliner harness electrical connector (1) to the cross-body wire harness. 26. Pass the communication interface module electrical connectors through the small hole in the carpet. 27. Install the headliner harness retaining clips to the rocker panel and the floor panel. 28. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right 'C' pillar. 2. Install the navigation antenna cable to the floor studs. 29. Install the body electrical block. 30. Install the rear carpet. Ensure that the carpet hooks over the left wheelhouse panel stud. 31. Connect the electrical connector to the left-hand body side window actuator. 32. Connect the electrical connector to the right-hand body side window actuator. Page 14219 For vehicles repaired under warranty, use the table. Disclaimer Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Page 15721 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 467 Memory Seat Module - Driver C4 Page 2923 3. Align the shoe of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117). 4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 5. Install the fixture EN 456850-401(4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block. 6. Install the bearing (3) and the nut (1). 7. Tighten the nut (1) to the bearing (3). Important: Use four old cylinder head bolts for the attaching bolts. 8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 Nm (11 lb ft). 9. Rotate the nut clockwise in order to remove the cylinder bore sleeve. 10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve (117) from the engine block. 11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117). 12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Page 14245 Memory Seat Module - Passenger C4 Page 4322 Electrical Symbols Part 4 Page 4779 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 4255 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Front Motor (W/Memory Seat) Page 10117 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14082 Tighten the sunroof module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the module. 4. Install the drive motor to the sunroof assembly. 5. With the aid of an assistant, install the sunroof assembly to the vehicle. Refer to Sunroof Replacement. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Page 7101 For vehicles repaired under warranty, use the table. Disclaimer Page 15142 Various symbols are used in order to describe different service operations. Page 14032 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Locations Page 5657 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 14329 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 4718 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 15679 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 15541 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Locations Locations View HVAC Systems - Manual Heater Control Valve: Description and Operation HVAC Systems - Manual COOLANT BYPASS VALVE The coolant bypass valve controls coolant flow to the auxiliary heater core. Integral to the coolant bypass valve is an electric solenoid that controls vacuum flow to open and close the valve. When the HVAC control module applies 12 volts to the integral solenoid, the solenoid applies vacuum to a diaphragm that closes the water valve. This action restricts coolant flow to the auxiliary heater core. The coolant bypass valve is normally open to allow coolant flow. Drivetrain - Front Drive Axle Squeal/Squeak Seals and Gaskets: Customer Interest Drivetrain - Front Drive Axle Squeal/Squeak Bulletin No.: 03-04-19-002B Date: April 04, 2005 TECHNICAL Subject: Squeak, Squeal or Whistle Noise from Front Axle (Replace Intermediate Axle Seal and/or Differential Carrier Seal) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer 4WD 2002-2005 GMC Envoy 4WD 2002-2004 Oldsmobile Bravada AWD Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 03-04-19-002A (Section 04 - Driveline/Axle). Condition Some customers may comment on a high pitched squeal, squeak or whistle noise in the front end of the vehicle. This noise usually occurs once per wheel revolution. This may be more common in cold weather below 5°C (40°F). The noise may be coming from the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal. For testing purposes, spraying a lubricant on the seal should temporarily reduce the noise. This noise should not be mistaken for a wheel bearing issue. Cause A lack of lubrication in the seal may cause this condition. Correction Replace the right front axle intermediate shaft housing outboard seal or the left outer differential carrier seal using the following procedure and part number listed below. Page 9793 C304 Part 2 C305 Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling The Inflatable Restraint Sensing And Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the main IP support by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP support. 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP support. Page 1401 Electrical Symbols Part 8 Page 10733 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 6367 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Locations Locations View Page 3952 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10087 14. Loosen the outer tie rods jam nuts (1). 15. Remove the outer tie rods (2) from the inner tie rods (3). Discard jam nut. Installation Procedure 1. Lubricate the inner tie rod (3) threads with a suitable chassis lubricant before installing the outer tie rod (2). 2. Install the new jam nuts (1) to the outer tie rods. 3. Install the outer tie rods (2) to the inner tie rods (3). 4. Install the power steering gear to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the power steering gear mounting bolts. Tighten the power steering gear mounting bolts to 110 Nm (81 ft. lbs.). Page 5315 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 3337 Timing Cover: Service and Repair Engine Front Cover Replacement ^ Tools Required J 44219 Cover Alignment Pins Removal Procedure 1. Drain the engine coolant. 2. Remove the cooling fan and the shroud. 3. Remove the drivebelt. 4. Remove the water pump. 5. Remove the crankshaft balancer. 6. Remove the power steering pump. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the oil pan. 9. Lower the vehicle. 10. Remove the 7 mm center bolt (1). 11. Loosen and remove the remaining engine front cover bolts. 12. Place two of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to release the front cover from the engine. 13. Remove the two bolts from the front cover. 14. Remove the oil pump. 15. Clean and Inspect the front cover. Installation Procedure 1. Install the J 44219, onto the engine. Page 14643 Front Door Weatherstrip: Service and Repair Front Door Opening REMOVAL PROCEDURE 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Page 14023 For vehicles repaired under warranty, use the table. Disclaimer Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Page 4301 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Audio System - Whine/Buzz Noise on Acceleration Technical Service Bulletin # 02-08-44-016A Date: 021201 Audio System - Whine/Buzz Noise on Acceleration File In Section: 08 - Body and Accessories Bulletin No.: 02-08-44-016A Date: December, 2002 TECHNICAL Subject: Whine, Buzz, Generator Whine, Whine Type Noise Heard on Acceleration (Repair Vehicle Sound System Wiring) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to December, 2001 This bulletin is being revised to change the model year. Please discard Corporate Bulletin Number 02-08-44-016 (Section 08 - Body and Accessories). Condition Some customers may comment on a buzzing or generator whine-type noise that emanates from the vehicle speakers with the radio on or off and when the headlights are on. This sound may be altered by changing the IP backlighting intensity (Dimming Function). Or, a noise emanates from the All-Wheel Drive system (if equipped), of 1 to 2 seconds duration during initial acceleration, at 24 km/h (15 mph) or at 48 km/h (30 mph). The generator whine-type noise may be observed at any time, however it is more noticeable when the electrical load on the system is high. Cause The cause of this condition may be EMI interference that is being transmitted to the radio system speakers from within the body wiring harness. Correction To determine which parts to order, you will need to inspect the vehicle. There are four types of audio systems available and three specific service wiring harness assemblies. ^ Bose(R) Premium Sound System with Rear Audio Controls ^ Bose(R) Premium Sound System without Rear Audio Controls ^ Non-Bose(R) Sound System with Rear Audio Controls ^ Non-Bose(R) Sound System without Rear Audio Controls See the Parts Information below for applicable part numbers. Parts Information Paris are currently available from GMSPO. Warranty Information Page 8568 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Page 10725 Electrical Symbols Part 1 Page 87 For vehicles repaired under warranty, use the table. Disclaimer Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 14792 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the evaporator core-auxiliary. 2. Remove the foam insulators (3) from the evaporator core-auxiliary lines. 3. Remove the foam insulators from the thermal expansion valve-auxiliary (4). 4. Using a back up wrench loosen the flare nuts from the thermal expansion valve-auxiliary. 5. Remove the auxiliary thermal expansion valve sensing bulb and retaining clip from the evaporator core-auxiliary lines. 6. Remove the thermal expansion valve-auxiliary from the evaporator core-auxiliary. IMPORTANT: Cap or tape the open A/C refrigerant lines immediately. 7. Remove and discard the O-ring seals from the evaporator core-auxiliary. Cap or tape the lines to prevent contamination of the evaporator core-auxiliary. INSTALLATION PROCEDURE 1. Remove the cap or tape from the evaporator core-auxiliary lines. 2. Install the new O-ring. 3. Install the thermal expansion valve-auxiliary onto the evaporator core-auxiliary lines. NOTE: Refer to Fastener Notice in Service Precautions. 4. Using a back up wrench, install the flare nuts from the evaporator core-auxiliary lines to the thermal expansion valve-auxiliary. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 6810 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 588 Correction 1. Re-Program the IPC following normal SPS procedures (TIS Version 8.0 released July 2002, or newer). 2. Clear all codes. 3. Disconnect the Tech 2 and return the vehicle to the customer. Warranty Information For vehicles repaired under warranty, use the table. Page 11943 Page 8282 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13321 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 16077 Parts are currently available from GMSPO. Disclaimer Page 3677 Electrical Symbols Part 6 Page 13979 Driver Door Module (DDM) C4 (W/Memory Features) Driver Door Module (DDM) C5 Page 10391 Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation. Loosen the shock module yoke to lower control arm retaining nut. Remove the shock module yoke from the lower control arm using J 36607. Pry the yoke away from the control arm to install the J 36607. Remove the J 36607 and the shock module yoke to lower control arm retaining nut. Remove the shock module from the shock tower and lower control arm. Installation Procedure Page 1663 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11277 23. Cut the side impact module left connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 24. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 25. Cut two 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the side impact module-left deployment harness. 26. Strip 13 mm (0.5 in) of insulation from both ends of these wires. 27. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. Page 6410 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 9018 Important: When performing the following service procedure, apply equal pressure to ensure proper seating of the reservoir and the pin holes are aligned. 3. Install the reservoir to the brake master cylinder. 4. Install the reservoir retaining pins. 5. Remove the brake master cylinder from the vise. 6. Install the brake master cylinder. Page 1870 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5597 Equivalents - Decimal And Metric Part 1 Page 16078 Tail Light Bulb: Service and Repair TAIL LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Remove the tail lamp assembly. 2. Place the tail lamp assembly onto a clean prepared surface. 3. Pull the bulb straight out in order to remove the tail lamp bulb from the socket assembly. INSTALLATION PROCEDURE 1. Install the tail lamp bulb to the socket assembly. 2. Ensure the bulbs are wiped clean and free of any oil or dirt. 3. Install the tail lamp assembly to the vehicle. 4. Check the bulbs for proper operation. Page 4077 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 6958 Page 11450 21. Remove the four push-in fasteners that attach the seat back panel to the seat back frame. 22. Remove the seat belt from the upper retractor bracket by sliding it through the slot. 23. Remove the bolt (1) attaching the upper seat belt bracket to the seat frame. 24. Remove the push-in fastener (2) from the retractor. 25. Remove the lower retractor bolt from the retractor. Page 869 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 8654 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Weatherstrip Replacement - Lift Gate Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. Installation Procedure 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 12874 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Page 8606 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 1210 Locations View - HVAC Systems - Automatic Page 4873 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12878 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Page 7683 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Position Sensor - Front Motor (W/Memory Seat) Position Sensor - Front Motor (W/Memory Seat) Page 11394 Locations View AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 15474 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 3739 7. Tighten each fastener a third time with the same sequence and torque. Parts Information Parts are currently available from GMSPO. Warranty Information DISCLAIMER Page 795 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 1754 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 14825 Electrical Symbols Part 2 Page 12115 Amplifier: Service and Repair Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the Left rear quarter trim panel. 2. Disconnect the electrical connectors from the radio speaker amplifier. 3. Remove the 4 bolts that retain the radio speaker amplifier to the body. 4. Remove the radio speaker amplifier from the body. INSTALLATION PROCEDURE 1. Install the radio speaker amplifier to the body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 bolts that retain the radio speaker amplifier to the body. Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connectors to the radio speaker amplifier. 4. Install the left rear quarter trim panel. Page 11838 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 10860 Control Assembly: Description and Operation HVAC Systems - Manual Air Delivery Description and Operation HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for Keep Alive Memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The Body Control Module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the features: AUXILIARY HVAC CONTROL MODULE The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range. Air Temperature Description and Operation HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for Keep Alive Memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The Body Control Module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the features: AUXILIARY HVAC CONTROL MODULE - VIN 6 The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range. Page 5174 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 14933 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8757 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 3694 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15976 Electrical Symbols Part 4 Page 7898 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Memory Seat Switch Replacement REMOVAL PROCEDURE Page 5419 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 7917 For vehicles repaired under warranty, use the table. Disclaimer Page 15911 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8885 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake hose bolt. 4. Install a plug in the front brake caliper hose in order to prevent excessive brake fluid loss and contamination. 5. Discard the metal/copper gaskets. DO NOT reuse them replace with NEW metal/copper gaskets. 6. Remove the front brake caliper mounting bolts. 7. Remove the front brake caliper from the mounting bracket. Installation Procedure Page 12742 INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. Page 14834 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 15465 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 8877 10. Remove the brake caliper mounting bracket. 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. Page 1545 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Propshaft Speed Sensor - Front Page 13455 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Specifications Fluid Pressure Sensor/Switch: Specifications Transmission Fluid Pressure Manual Valve Position Switch to Valve ........................................................................................ 8.0-14.0 Nm (6-10 ft. lbs.) Page 14599 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 5682 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Diagrams Door Lock Cylinder Switch - Driver Diagrams Door Lock Cylinder Switch - Driver HVAC System - Manual Air Door Actuator / Motor: Description and Operation HVAC System - Manual Air Distribution Control The HVAC control module controls the distribution of air by the use of a defrost actuator and a mode actuator. The modes that may be selected are: ^ Defrost ^ Defog ^ Panel ^ Bi-Level ^ Floor The mode and defrost actuators are connected to the mode and defrost doors by a cam type linkage system. Depending on the position of the door, air is directed through the HVAC module and distributed through various ducts leading to the outlets in the dash. If the HVAC control module detects a fault with the mode or defrost doors the HVAC control module will try to drive the actuator for a predetermined amount of time, to defrost, which is the defaulted position for the mode and defrost door actuators. When the mode switch is placed in the defrost or defog positions the A/C is commanded on and the recirculation door is moved to the outside air position to help reduce window fogging. A/C is available in all modes and recirculation is only available in the panel and bi-level modes. Mode Actuator The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5-volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. Defrost Actuator The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit Zero volts drives the actuator in one direction while 5-volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position. Front Defrost When defrost is selected, the A/C compressor is activated. The A/C compressor clutch will engage when ambient temperatures are above 3°C (38°F). The blower motor will be activated, regardless of the coolant temperature. The HVAC control module will override the auxiliary HVAC control module so a high volume of air is delivered to the front defrost vents. The rear window defogger does not affect the HVAC system. HVAC Control Actuator Descriptions DEFROST ACTUATOR The defrost actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. MODE ACTUATOR The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AUXILIARY MODE ACTUATOR The auxiliary mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5 volt reference, Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 15653 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Locations View Page 4131 Electrical Symbols Part 2 Page 8328 Page 14510 Seat Lumbar Motors And Position Sensors Assembly - Driver Page 7160 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 11686 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 5639 16.2. Turn OFF the ignition, for 10 seconds. 16.3. Turn ON the ignition, with the engine OFF. 16.4. Inspect for fuel leaks. 17. Install the fuel tank shield, if equipped. Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: All Technical Service Bulletins A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 14780 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 12629 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4209 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 6674 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 1642 Electrical Symbols Part 6 Page 5564 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the Underhood Compartment above the left front wheel well. Page 13097 Rear Door Weatherstrip: Service and Repair Rear Door Opening REMOVAL PROCEDURE 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Page 6073 For vehicles repaired under warranty, use the table. Disclaimer Page 15915 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Air Suspension Sensor - LR Locations Locations View Page 7893 For vehicles repaired under warranty, use the table. Disclaimer Page 4262 Equivalents - Decimal And Metric Part 1 Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 10251 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5961 Knock Sensor: Connector Views Knock Sensor (KS) 1 Front Knock Sensor (KS) 2 Front Page 3653 Engine Coolant Temperature (ECT) Sensor Page 1097 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Page 14061 Memory Seat Module - Passenger C3 Page 7052 Page 2471 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 9875 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 10764 1. Install the blower motor-auxiliary (1) to the HVAC module-auxiliary (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). Connect the electrical connectors (3,4). 3. Install the retaining bolts (5) to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the HVAC module-auxiliary retaining bolts (5). Tighten Tighten the bolts to 10 N.m (88 lb in). 5. Install the retaining nuts (4) to the HVAC module-auxiliary (1) under the vehicle. Tighten Tighten the nuts to 10 N.m (88 lb in). 6. Install the right rear quarter trim. Page 1421 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 1096 Seat Lumbar Motors And Position Sensors Assembly - Driver Page 4285 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 8858 Various symbols are used in order to describe different service operations. Page 14521 Lumbar Adjuster Switch - Driver(W/O Memory Seat) Lumbar Adjuster Switch - Passenger(W/Memory Seat) Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Body - Door(s) Are Difficult To Close Rear Door Striker: All Technical Service Bulletins Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 395 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 7290 Valve Body: Specifications Valve Body to Case Bolt .............................................................................................................................................................. 8.0-14.0 Nm (6-10 ft. lbs.) Page 16038 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Malfunction Indicator Lamp (MIL) Always On - Steps 1-6 Page 5987 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11166 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 14241 Memory Seat Module - Driver C4 Page 11430 Page 443 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6039 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 12529 Procedures Trunk / Liftgate Lock Cylinder: Procedures The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Note: When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. Page 40 Page 8939 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Important: Do NOT refinish the brake rotors in order to correct any of the following complaints: ^ Growl or squeal brake noise ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the rotor braking surface ^ Rotor discoloration Refinish the brake rotors ONLY when one or more of the following conditions exist: ^ Groove depth in excess of specification ^ Severe scoring of the rotor braking surface ^ Brake pulsation caused by the following: ^ Lateral runout in excess of specification ^ Brake rotor thickness variation in excess of specification ^ Corrosion or pitting that is deeper than the rotor braking surface 1. Use the J 42450-A in order to clean the wheel bearing/hub. 2. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 3. Use the J 41013 in order to THOROUGHLY clean the rust from the brake rotor flange. 4. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 5. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher, if available, in order to create a non-directional braking surface. 6. Clean the braking surfaces with GM P/N 12377981, Canadian P/N 10953463, or equivalent brake parts cleaner. Page 1887 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or fails within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 794 Electrical Symbols Part 8 Service and Repair Service 4WD/AWD Indicator Lamp: Service and Repair Service AWD/4WD Indicator Lamp Illumination of the Lamp indicates a problem with the drive system. There will probably be a Transfer Case Code set to aid in diagnostics. The only way to get the light to go off is to clear Transfer Case codes. This light can NOT be shut off or reset any other way. Transfer Case codes should be read and repaired before clearing them. Refer to Transfer Case. See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Page 2593 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 6884 Disclaimer A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8229 6. Pry the front out shaft seal from the transfer case. 7. Remove the front output shaft seal from the transfer case. Installation Procedure 1. Install the J 45236 on the front output shaft. Page 12865 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 2194 Electrical Symbols Part 3 Electrical - Intermittent Multiple Malfunctions Multiple Junction Connector: Customer Interest Electrical - Intermittent Multiple Malfunctions File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-017 Date: August, 2002 TECHNICAL Subject: No Start, Service Engine Soon Lamp On, ABS Warning Light On, Air Bag Light On, DTCs Set, Various Door Electrical Functions Inoperative (Replace Driver and/or Passenger Door Harness and/or Repair Body Harness Connector) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT, TrailBlazer Export 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Built Prior to April, 2002 Condition Some customers may comment that the vehicle will not start and/or any of the following door electrical functions may be inoperative: ^ Power Door Locks ^ Outside Mirrors ^ Memory Seat ^ Power Windows ^ Heated Front Seats ^ Door Audio Speaker ^ Liftgate Some may comment that these conditions occur intermittently. Diagnosis of these conditions may also find that various Diagnostic Trouble Codes (DTCs) may be set. Cause Moisture intrusion through the passenger side and driver side front door-to-body harness inline connections. Correction Follow the recommended diagnostics/repair for the front door and body harness connectors listed below. Driver Door 1. Inspect the driver door harness connector (9 or 11 wires depending on vehicle option content) and terminals (inline to body harness). ^ If the connector has 11 leads, then there is no issue. Proceed to Passenger Door. ^ If the connector has 9 leads, then verify that the three empty cavities of the plastic connector are properly blocked. If all three cavities are blocked, then there is no issue. Proceed to Passenger Door. If two cavities are open, then perform the following repair procedure. - If there is no evidence of corrosion, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. - If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors subsection of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (11 wires) and terminals (inline to driver door harness). If there is evidence of corrosion, replace the mating Page 12556 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 4892 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 15571 Page 7878 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 11113 Locations View - HVAC Systems - Manual Page 3893 Fuse Block-Underhood (Six Cylinder Engine, 4.2L) The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the Underhood Compartment above the left front wheel well. Page 2916 The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Refer to the illustration above. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. 2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves. Page 1534 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4508 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 15639 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14407 15. Install the 4 retaining nuts to the studs on the underside of the cushion. Tighten Tighten the nuts to 25 N.m (18 lb ft). 16. Install the 3 seat switch bezel screws. Trailblazer, Envoy, and Bravada TOOLS REQUIRED J 36796 Clip Removal Tool REMOVAL PROCEDURE 1. Remove the seat cushion from the vehicle. 2. Remove the seat cushion bracket. 3. Remove the seat latch bezels. 4. Use the J 36796 to remove the push pins (1) on the underside of the seat bottom, in order to start the seat cushion removal procedure. Page 1640 Electrical Symbols Part 4 Page 9570 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 6166 Spark Plug: Specifications Ignition System Specifications Page 4572 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12417 Exhaust - Exhaust Noise/Leak Exhaust Manifold Gasket: Customer Interest Exhaust - Exhaust Noise/Leak File in Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-032 Date: October, 2002 TECHNICAL Subject: Exhaust Noise/Leak (Replace Exhaust Manifold Fasteners and Gasket) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) and Automatic Transmission (RPO M30) Built from Start of Production to January, 2002 Condition Some customers may comment on an exhaust noise or exhaust leak. The noise will appear to come from the area of the exhaust manifold. Cause The fasteners used to hold the exhaust manifold may have relaxed and lost clamping power. The manifold will then be allowed to move under certain conditions causing a small leak. Correction Install a new exhaust manifold gasket and fasteners. Use the part numbers listed below. The new fasteners have the proper adhesive in patch form already on the threads. DO NOT use any additional thread lock material. 1. Remove the exhaust manifold fasteners and gasket and dispose of properly. 2. Make sure the manifold bolt holes in the cylinder head are clean of debris or foreign material. 3. Install a new exhaust manifold gasket. 4. Install the exhaust manifold using new fasteners. 5. Tighten all fasteners in sequence to 20 N.m (15 lb ft). 6. Tighten each fastener a second time with the same sequence and torque. Page 9647 Fuse Block - Rear C4 Page 13707 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 12166 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 14826 Electrical Symbols Part 3 Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 404 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 1220 Ambient Temperature Sensor / Switch HVAC: Service and Repair Air Temperature Sensor Replacement - Upper Left REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Page 14962 Electrical Symbols Part 1 Page 13855 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 6834 For vehicles repaired under warranty, use the table. Disclaimer Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 8783 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 2217 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4064 Electrical Symbols Part 5 Page 13151 8. Open the hood and install the prop rod. 9. Install the left and right adjustable rubber bumpers and adjust them all the way down. 10. Close the hood and verify adjustment. The bumpers are required to make contact with the hood. Adjust if necessary. 11. Apply white lithium grease to the bottom of the V on the latch. Refer to illustration above. 12. Verify the final adjustment by grabbing the hood and jiggling it up and down. If a rattle is heard, perform the procedure again. 13. Install the grille. Refer to Grille Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9099 1. Remove the plastic cover from the side rail front corner (2) and inspect the attaching bolt (1) for being overtightened. If the bolt is overtightened, it will appear to be partially recessed into the plastic mounting surface. 2. If this condition is found, remove the bolt and install a flat washer (3), P/N 120385 or equivalent, on the attaching bolt. 3. Install the bolt and washer. Tighten Tighten the bolt to 5 N.m (44 lb in). Part number 120385 is a flat washer with an outside diameter of 14 mm (9/16 in), a hole diameter of 6.5 mm (1/4 in), and a thickness of 1.2 mm (3/64 in). If using an equivalent washer, be sure it has adequate corrosion protection. Correction # 2 Position the rear cross bow (1) at the very rear of the side rails as shown. Position the front cross bow (2) in the middle (3) of the second door (4) opening. Page 4170 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the heated oxygen sensor. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Page 14916 DISCLAIMER Page 9802 C315 Part 2 C316 C500 - C599 Page 9496 C700 Page 1764 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Body - Front Bumper Fascia Panel Wavy Front Bumper Cover / Fascia: All Technical Service Bulletins Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Page 10553 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). Page 9220 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10736 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 3047 Engine Mount: Service and Repair Engine Mount and Bracket Replacement- Right Engine Mount and Bracket Replacement- Right ^ Tools Required J 41240 Fan Clutch Remover and Installer Removal Procedure 1. Disconnect the battery negative cable. 2. Using the J41240 to secure the water pump pulley. Loosen the cooling fan hub nut from the water pump shaft. 3. Remove the MAP sensor electrical connector and retainer (1). 4. Remove the MAP sensor (2). 5. Remove the right shock module, if frame engine mount is being removed. Page 8438 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Transfer Case Speed Sensor Replacement - Front (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 1514 Electrical Symbols Part 5 Page 9326 1. Install the starter motor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the starter motor mount bolt and nut. Tighten Tighten the starter mount bolt and nut to 50 N.m (37 lb ft). 3. Connect the positive battery cable to the starter and secure the cable with a nut. Tighten Tighten the positive cable nut to 9 N.m (80 lb in). 4. Install the left tire. 5. Connect the battery negative cable. Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 15894 License Plate Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 9234 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 302 Page 6046 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. Fuel Filler Cap The fuel fill pipe has a tethered quarter-turn type fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Page 4559 Electrical Symbols Part 6 Page 10755 Equivalents - Decimal And Metric Part 1 Page 13491 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts (2) retaining the rear of the floor console bracket to the floor weld studs. Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the center pillar trim panels. 9. Install the front side door sill plates. 10. Pass the communication interface module electrical connectors through the small hole in the carpet. 11. Pass the body electrical block electrical connectors through the small hole in the carpet. 12. Install the body electrical block. 13. Install the carpet ensuring that the carpet hooks over the left wheelhouse panel stud. 14. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 15. Install the right rear quarter lower trim panel. 16. Install the left rear quarter lower trim panel. 17. Install the left/right rear body side trim rear window garnish molding. 18. Install the left/right front body side window garnish molding 19. Install the lift gate door sill plate. 20. Install the cargo tie-down loops and secure the loops with the tie-down bolts. Tighten the bolts to 35 N.m (26 lb ft). Page 5836 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 10108 Electrical Symbols Part 8 A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 10102 Electrical Symbols Part 2 Page 4991 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9365 Fuse Block - Rear C2 Part 1 Page 2450 10. Remove the power steering hose assembly bracket retaining bolt at the wheel well. 11. Disconnect the power steering hose assembly bracket from the wheel well. 12. Remove the power steering hose assembly to frame brackets retaining bolts. 13. Remove the power steering hose assembly to front crossmember bracket mounting bolt. 14. Remove the power steering pressure hose (1) and power steering cooler hose (2) from the power steering pump. 15. Remove the power steering hose assembly from the vehicle. Installation Procedure 1. Install the power steering hose assembly to the vehicle. 2. Install the power steering cooler hose (2) to the power steering pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose (1) to the power steering pump. Tighten the power steering pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). Page 693 Body Control Module: Description and Operation The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the Driver Door Module (DDM), Passenger Door Module (PDM) and the Liftgate Module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 1420 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15500 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: All Technical Service Bulletins Rearview Mirrors (Outside) Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 15887 Electrical Symbols Part 2 Page 850 Disclaimer Page 3237 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9518 Locations View Page 11837 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 7772 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5306 Electrical Symbols Part 5 Specifications Sensor Resistance Table - HVAC Systems - Automatic A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 9598 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement Trailblazer, Envoy, and Bravada TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor suction/discharge hose nut (3). 3. Remove the compressor suction/discharge hose from the compressor (4). 4. Remove the sealing washers. 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the O-ring seals. 12. Cap or plug all of the open connections. INSTALLATION PROCEDURE Page 12890 Front Door Interior Handle: Service and Repair Door Handle Replacement - Inside Door Handle Replacement - Inside Removal Procedure 1. Remove the door trim panel. 2. Remove the handle retaining bolt. 3. Release the handle locator tab from the locator cutout, by sliding the handle forward. 4. Release the rod retainer locks. 5. Remove the rods from the handle. 6. Remove the handle from the door. Installation Procedure 1. Position the handle to the door. 2. Install the rods to the handle. 3. Install the rod retainer locks. 4. Insert the handle locator tab into the locator cutout and move the handle rearward, indexing the fastener hole to the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the handle retaining bolt. Tighten bolt to 10 N.m (88 lb in). 6. Install the door trim panel. Page 11494 2. Install the seat belt retractor bracket bolt (1) to the bracket and seat back frame. Tighten Tighten the seat belt retractor bracket bolt to 55 N.m (40 lb ft). 3. Position the seat belt retractor assembly onto the seat back frame. 4. Install the push pin on the seat back retractor to the seat back frame. 5. Install the rear seat belt center retractor nut. Tighten Tighten the rear seat belt center retractor nut to 35 N.m (26 lb ft). Page 3869 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 11165 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 7749 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 2672 Oil Change Reminder Lamp: Service and Repair To reset the CHANGE ENG OIL light, do the following: 1. Turn the ignition key to run with the engine off. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat procedure. Page 1602 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 12551 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 335 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 5942 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: All Technical Service Bulletins A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 411 Door Module: Connector Views Driver Door Module (DDM) Driver Door Module (DDM) C1 Page 7536 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 9505 Locations View Page 15280 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 6241 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Seat Belt Replacement Seat Belt: Service and Repair Seat Belt Replacement Front Seat REMOVAL PROCEDURE 1. Remove the seat switch bezel. 2. Remove the seat trim panel. 3. Remove the seat belt anchor nut from the seat adjuster assembly. 4. Remove the screw from the front seat back seat belt bezel. 5. Slide the bezel off the seat belt. Page 12912 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). 8. Hand tighten all of the 4 supplied bolts (4). Notice: Refer to Fastener Notice in Service Precautions. 9. Align the hinge to the original scribe location. Tighten the bolts to 25 N.m (18 lb ft). 10. Clean and prepare all bare-metal surfaces. 11. Apply a full-bodied caulk around the service hinge. 12. Refinish as necessary. 13. Install and align all of the related panels and components. GM Oil Life System (TM) - Resetting Maintenance Reminder Control Module: Technical Service Bulletins GM Oil Life System (TM) Resetting File In Section: 00 - General Information Bulletin No.: 02-00-90-001 Date: March, 2002 INFORMATION Subject: GM Oil Life System(TM) - Resetting Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada These vehicles have an oil life monitor. The GM Oil Life System(TM) will show when to change the engine oil and oil filter. The GM Oil Life System(TM) must be reset after changing the engine oil and oil filter. Resetting Procedure The current Owner's Manual contains the following reset procedure: 1. Turn the ignition to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. However, it has been found that after completing the reset procedure, the CHANGE ENG OIL light does not flash as stated in the vehicle Owner's Manual. If the CHANGE ENG OIL light goes out after the reset procedure and does not return after the next ignition cycle, then the system has been reset. If the vehicle is equipped with a Driver Information Center (DIC), then reset confirmation can also be done by verifying that the Engine Oil Life percentage value has reset to 100%. Use the above information to prevent the inadvertent replacement of the instrument cluster if there are comments that the oil life reset feature does not work. Disclaimer Page 10181 Steering Shaft: Service and Repair "For information regarding this component please refer to steering column service and repair" LF Luggage Carrier - Windnoise Roof Rack Frame: All Technical Service Bulletins Luggage Carrier - Windnoise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-58-004 Date: September, 2001 TECHNICAL Subject: Windnoise or Gap Between Luggage Carrier Side Rail Front Cover and Roof Sheet Metal (Secure Front Side Rail Corners and/or Reposition Cross Bows) Models: 2002 Chevrolet and GMC SIT Utility Models (Trail Blazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment about wind noise coming from the roof or luggage carrier area when driving at highway speeds. Also comments may be received about a gap between the luggage carrier side rail front cover(s) and the roof sheet metal. Cause One or both of the following may cause the conditions: Cause # 1 The bolt attaching the luggage carrier side rail front corner (1) may be over tightened, causing the mounting surface to lift up leaving a gap (3) between it and the roof sheet metal (2). This can occur on either the left or right side rail front corner. Cause # 2 The luggage carrier front (2) and rear cross bows (1) are not positioned correctly when not in use. Correction Correction # 1 Page 5914 Locations View Page 12997 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill only through the hinge base (1). Do not drill through the mating surface (2). 6. Remove the hinge tab (3) before drilling, if necessary. 7. At each punch location, drill a 3-mm (1/8-in) pilot hole (1). 8. Using the pilot hole as a guide, drill through the hinge base using a 19-mm (3/4-in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 9. Remove the hinge. Page 9470 C311 C312 Part 1 Page 5273 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 9600 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 9928 Frame Angle Measurement (Express / Savana Only) ........ Page 5587 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 3143 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 2061 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the left coat hook. NOTE: In order to avoid damaging the antenna lead connector, follow these guidelines: Use a plastic tool and carefully pry the connector from the window. - Do NOT pull on the connector, which may be stuck to the urethane adhesive or the headliner. 2. Disconnect the radio antenna module electrical connector from the stationary glass. 3. Release the rear headliner to roof retainers. 4. Lower the rear of the headliner far enough to access the radio antenna module located on the left side of the vehicle. 5. Disconnect the electrical connector from the radio antenna module. 6. Disconnect the coax cable from the radio antenna module. 7. Remove the radio antenna module from the headliner retaining strips. 8. Remove the radio antenna module from the vehicle. INSTALLATION PROCEDURE Page 9659 Fuse Block: Service and Repair REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. If replacing the rear electrical center on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 11685 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 14688 10. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. 4. Attach the molding to the outside of the door with double sided tape. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip 9. Install the inner window belt sealing strip. 10. Install the trim panel. Page 9418 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 11657 Disclaimer Locations Locations View Page 3698 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 14353 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 12440 Circuit/System Testing Component Testing Page 1689 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 9551 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove the shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 15. Lift the console, disconnect the wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (TrailBlazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Light Blue wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Yellow wire. Page 11831 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 5762 Throttle Body: Service and Repair THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the resonator assembly from the throttle body. 2. Remove the evaporative emission (EVAP) canister purge line from the throttle body. 3. Disconnect the throttle body electrical connector. 4. Remove the throttle body assembly refraining fasteners. 5. Remove the throttle body assembly (2) and the gasket from the intake manifold. 6. Clean the gasket surface. INSTALLATION PROCEDURE 1. Install the throttle body assembly to the intake manifold with the gasket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the throttle body assembly retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). Page 15810 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 11080 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 14210 13. If the Tech 2 does not communicate with the driver seat module ("No Communications with Vehicle Check Diagnostic Link Connector Check Ignition (On/Off)"), the module is possibly locked due to a logic lockup. Remove the LGM/DSM (Lift Glass Module/Driver Seat Module) fuse. This fuse is also the fuse for the Passenger Seat Module; 10 AMP, fuse # 6 from the Rear Underseat Fuse Block. 14. Verify that the fuse is not open. If OK, wait 30 seconds before reinstalling the fuse. 15. Attempt to move the seat. If the seat now moves or the Tech 2 now establishes communication with the driver seat module, you should replace the seat module using the procedure below. If not, use normal SI service diagnostics to determine why the seat is inoperable. Memory/Heated Seat Module Replacement Replace the memory/heated seat module using the procedure listed below. 1. Position the driver's front seat in the full up-right position. If the seats are inoperative, you may be able to re-initialize the seat module by disconnecting the seat module wiring harness from the seat module at the front edge of the seat cushion for 30 seconds. 2. Remove the three screws that attach the seat switch bezel to the seat cushion assembly and set aside. 3. Remove the four nuts that attach the seat cushion pan to the seat assembly. 4. Remove the production aid seat clip from the front outboard stud and discard (if equipped). 5. Position the seat pan to access the seat module retaining screw and remove the screw. 6. Disconnect the electrical connectors from the seat module. 7. Connect the electrical connectors to the new seat module. 8. Reinstall the seat module retaining screw. Tighten Tighten the screw to 3 N.m (26 lb in). 9. Position the seat pan to the seat assembly and install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Reposition the seat switch bezel and install the three retaining screws. Tighten Tighten the screws to 3 N.m (26 lb in). 11. Lower the seat to the normal position. 12. If the vehicle is equipped with heated seats, perform all steps on the front passenger side seat as well. Parts Information Parts are currently available from GMSPO. Warranty Information Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 5732 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. A/T - Oil Cooler Flushing Frequently Asked Questions Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Page 6670 Page 10729 Electrical Symbols Part 5 Page 2795 ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 61 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 8869 Page 12136 4. Inspect the harness at the pinched location (2) and repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 5. Verify proper installation of the harness clip (1) that attaches the harness to the body. Reinstall if necessary. 6. Install the carpet back into place. 7. Install the right rear door sill plate. 8. Install the right rear seat back. Refer to the Seats sub-section of the Service Manual for the Seat Back Replacement procedure (SI2000 Document ID # 741140). Parts Information Parts are expected to be available from GMSPO October 15, 2001. Warranty Information For vehicles repaired under warranty, use the table. Front Wheel Bearing Replacement Wheel Bearing: Service and Repair Front Wheel Bearing Replacement Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the brake rotor. 6. Disengage the wheel drive shaft from the wheel hub and bearing. Place a brass drift against the outer end of the wheel drive shaft in order to protect the wheel drive shaft threads. Sharply strike the brass drift with the hammer. Do not attempt to remove the wheel drive shaft from the wheel hub and bearing at this time. Page 1705 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 1872 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 7019 For vehicles repaired under warranty, use the table. Disclaimer Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12649 Passlock Sensor Page 2036 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 225 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 4146 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1868 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1519 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5319 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 8477 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10122 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9651 Fuse Block - Underhood C3 Page 7407 22. Secure the large retaining clamp (2) and the boot (3) to the housing (1) using J 35566. 23. Remove the convolute retainer from the boot (l). Page 12238 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 5753 Equivalents - Decimal And Metric Part 1 Page 11840 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 9858 27. Remove the CPA from the rear audio control connector and remove the eight wires from the designated cavities of the rear audio control in-line harness connector and replace them with the wires from the new harness as listed below. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. Also, this wiring harness has two Dark Blue and two Brown wires. It may be necessary to cut a small portion of the electrical tape wrap to determine which wires are paired. ^ Pair One - Remove wire in cavity B3 and insert the Brown/White wire. - Remove wire in cavity A8 and insert the Brown wire. ^ Pair Two - Remove wire in cavity A9 and insert the Dark Blue wire. - Remove wire in cavity A1 and insert the Black wire. ^ Pair Three - Remove wire in cavity B1 and insert the Brown wire. - Remove wire in cavity B5 and insert the Yellow wire. ^ Pair Four - Remove wire in cavity B6 and insert the Light Blue wire. - Remove wire in cavity B2 and insert the Dark Blue wire. ^ Replace the CPA. ^ Cut off all removed terminals and wires as close to the taped portion of the original harness as possible. 28. Lift the carpet in the left rear door area, and slide the rear electrical center through the cutout in the carpet. Continue lifting the carpet enough to gain access to the three in-line connectors located inboard of the rear electrical center. 29. Locate the 8-way connector with the purple CPA. Separate the connector and remove the CPA from the female side of the connector. 30. Route the new harness under the carpet from the rear of the console to the 8-way connector. 31. Remove the eight wires from the 8-way inline harness connector and replace them with the wires from the new harness. Important: These wires are twisted pairs and they must be positioned properly in the connector or audio system performance will be affected. ^ Remove wire in cavity A and insert the Gray wire. ^ Remove wire in cavity B and insert the Tan wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Light Green wire. ^ Remove wire in cavity E and insert the Yellow wire. ^ Remove wire in cavity F and insert the Brown wire. ^ Remove wire in cavity G and insert the Light Blue wire. ^ Remove wire in cavity H and insert the Dark Blue wire. ^ Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. Page 4583 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 9868 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 4791 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3843 Electrical Symbols Part 2 Page 6005 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 1329 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 4768 Electrical Symbols Part 2 Page 9661 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the block base retaining nuts to the floor studs. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 6117 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 751 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 13756 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Page 170 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 15768 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9899 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove the shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 15. Lift the console, disconnect the wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (TrailBlazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Light Blue wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Yellow wire. Page 1720 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2044 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Page 10345 8. Loosen the air spring level sensor to the frame mounting bolts. Important: If not equipped, use a new anti-rotation bolt (P/N 11569736). 9. Loosely install the sensor mounting bolts with the anti-rotation bolt in the right hand mounting hole. Notice: Refer to Fastener Notice in the Preface section. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly mounted and aligned. 10. Install the air spring level locating pin. A 4 mm drill bit or equivalent can be substituted. Tighten 1. While holding the body of the sensor, tighten the anti-rotation bolt first. 2. Tighten the air spring level sensor frame mounting bolts to 8 Nm (71 lb in). Page 6106 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5286 Conversion - English/Metric Page 8912 WARRANTY INFORMATION Page 5220 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Locations Locations View Service Precautions Vehicle Lifting: Service Precautions Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. - Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 15264 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9526 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 10623 Locations View - HVAC Systems - Automatic Air Spring Sensor Calibration Air Spring: Service and Repair Air Spring Sensor Calibration Rear Air Spring Level Sensor Calibration 1. Raise and support the vehicle. 2. Remove the rear tire and wheels. 3. Lower the vehicle with the rear axle supported by the jackstands. 4. Raise or lower the vehicle until the D-height measurement is 25 mm (1 in) above the published D-height specification 160 mm (6.33 in). 5. Turn the ignition key to the ON position. This will partially deflate the air spring. 6. After two minutes, turn the ignition key to the OFF position and remove the air suspension fuse. Important: A D-height gauge block (1) can be used to determine the D-height position. Create a D-height gauge block using metal stock to 20 mm X 30 mm X the published D-height specification 135 mm (5.33 in). Use the block (1) as a measuring device only. 7. Raise or lower the vehicle so that the left side D-height is at a published specification 135 mm (5.33 in). Page 4584 Equivalents - Decimal And Metric Part 1 Page 8758 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case right rear speed sensor electrical connector. 3. Remove the transfer case speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 9469 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 137 Page 10105 Electrical Symbols Part 5 Page 4456 1. Install the air cleaner element (1) onto the air cleaner outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element and air cleaner outlet duct into the lower air cleaner housing/washer solvent tank assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the air cleaner cover/resonator assembly (1). Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator support cover. Page 11126 Locations View - HVAC Systems - Automatic Page 13696 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4601 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. Refer to Generator Replacement in Starting and Charging. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System. Page 15134 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 1469 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 8051 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 6503 HVAC Systems - Manual Blower Motor Control Processor - Auxiliary (Body Type VIN 6) Page 6908 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 4359 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Locations Locations View Page 5572 Electrical Symbols Part 6 Page 11175 Locations View - HVAC Systems - Automatic Page 7229 4. Remove the transmission jack. 5. Install the nuts securing the transmission mount to the transmission support. ^ Tighten the nuts to 46 Nm (35 ft. lbs.). 6. Lower the vehicle. Page 6097 Electrical Symbols Part 1 Page 15086 Malfunction Indicator Lamp (MIL) Inoperative - Steps 1-7 Page 12630 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Remove the PCM. 2. Remove the coolant heater cord from the engine harness bracket (1). 3. Remove the coolant heater cord from the coolant heater (2). 4. Remove the coolant heater cord from the battery cover (1). Installation Procedure 1. Install the coolant heater cord to the coolant heater. Install the coolant heater cord to the engine harness bracket (1). Page 9474 Multiple Junction Connector: Diagrams C100 C100 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 13265 Disclaimer Diagrams Hood Ajar Switch (Export) Page 15197 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 9876 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 761 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 3142 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 6205 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 23458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 9547 43. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 44. Turn the key OFF. Remove the key. 45. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 46. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 47. Reinstall the rear electrical center cover. 48. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 49. Reinstall the knee bolster (TrailBlazer). 50. Reinstall the closeout/insulator panel (TrailBlazer). 51. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 52. Reinstall the console to the vehicle and install the retainers. 53. Reinstall the shift boot and handle assembly. 54. Reinstall the console bin and retainers. 55. Reinstall the first lock pillar trim and carpet retainers to both door openings. 56. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 57. Install the IP upper trim panel and windshield pillar moldings. 58. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 59. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios With Rear Audio Controls These vehicles use wiring harness P/N 15164933. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. Memory Seat Module - Driver Power Seat Control Module: Diagrams Memory Seat Module - Driver Memory Seat Module - Driver C1 Page 4274 Electrical Symbols Part 2 Page 2754 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 7654 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Page 1605 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 5618 Disclaimer Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt 37 ft. lbs. Page 1737 Electrical Symbols Part 3 Page 2913 6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117). 7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401(1). Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680403 assembly or damage to the cylinder bore sleeve will occur. Page 4544 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. Page 5302 Electrical Symbols Part 1 Page 14269 Position Sensor - Recline Motor (W/Memory Seat) Page 11062 Refrigerant Oil: Service and Repair Compressor Oil Balancing DRAINING PROCEDURE IMPORTANT: Drain and measure as much of the refrigerant oil as possible from the removed compressor. 1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean, graduated container. Rotate the compressor shaft to assist in draining the compressor. 2. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor. 3. Properly discard the used refrigerant oil. BALANCING PROCEDURE IMPORTANT: The refrigerant oil in the A/C system must be balanced during compressor replacement. 1. The replacement compressor is shipped with 74 ml (2.5 oz) of refrigerant oil. 2. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is: ^ Less than 74 ml (2.5 oz) Leave the 74 ml (2.5 oz) in the replacement compressor. ^ More than 74 ml (2.5 oz) Add to the compressor the difference between the 74 ml (2.5 oz) and the amount drained. Page 5442 Tighten Tighten the fuel tank shield fasteners to 25 N.m (18 lb ft). Page 910 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 4072 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Inflatable Restraint Side Impact Sensor Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Page 14560 Air Dam: Service and Repair Air Dam Replacement - Front (Chevrolet , GMC) Air Dam Replacement - Front (Chevrolet, GMC) Removal Procedure 1. Remove the front fascia. 2. Remove the impact bar. 3. Disengage the tabs on the air deflector from the slots in the impact bar. 4. Remove the air deflector from the impact bar. Installation Procedure 1. Install the air deflector to the impact bar. 2. Insert the tabs on the air deflector to the slots in the impact bar. 3. Install the impact bar. 4. Install the fascia. Transfer Case Fluid Replacement (Trailblazer, Envoy) Fluid - Transfer Case: Service and Repair Transfer Case Fluid Replacement (Trailblazer, Envoy) Transfer Case Fluid Replacement (Trailblazer, Envoy) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the drain plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drain plug. ^ Tighten the plug to 27 Nm (20 ft. lbs.). 3. Fill the transfer case with the proper fluid. Refer to Capacities - Approximate Fluid on page 4-255. Page 1551 Manifold Absolute Pressure (MAP) Sensor Page 10522 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 4295 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 8784 Part 2 of 2 Page 4798 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 15762 Electrical Symbols Part 4 Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Page 15572 Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Lift Gate Window Liftgate Window Glass Weatherstrip: Service and Repair Lift Gate Window REMOVAL PROCEDURE 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. INSTALLATION PROCEDURE 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Page 8920 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Inflatable Restraint Side Impact Sensor Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Page 15876 High Beam Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the high beam relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the high beam relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 15393 Electrical Symbols Part 2 Page 9324 Conversion - English/Metric Page 4342 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8331 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Page 14065 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the seat control module to the seat pan. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Interior - Console Power Outlet Cover/Seat Interference Console: Customer Interest Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 3219 Electrical Symbols Part 8 Page 8424 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 4329 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 3967 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 8392 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer Ext, Envoy XL) Transfer Case Motor/Encoder Replacement (Trailblazer EXT, Envoy XL) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/Encoder is in the neutral position. 1. Raise the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the motor/encoder electrical connector. 4. Remove the motor/encoder mounting bolts. 5. Remove the motor/encoder assembly. Installation Procedure Page 12925 Front Door Panel: Service and Repair Panel Replacement Side Front Door TOOLS REQUIRED J 36796 Clip Removal Tool REMOVAL PROCEDURE 1. Remove the accessory switch panel. 2. Remove the 2 trim panel retaining bolts. 3. Use the J 36796 in order to release the 9 trim panel fasteners from the door. 4. Remove the trim panel from the door. 5. Remove the inside door handle bezel. 6. Remove the outside rear view mirror (ORVM) switch, if equipped. INSTALLATION PROCEDURE 1. Install the ORVM switch, if equipped. 2. Install the inside door handle bezel. 3. Install the door trim panel to the door, as follows: 3.1. Install the panel on the door by placing the upper flange into the belt seal lip. 3.2. Install the rear upper retainer first. 3.3. Install the forward upper retainer second. Page 5829 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 508 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Nuts 18 ft. lbs. Page 2234 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 8230 2. Align the front output shaft seal on the J 45236-2 (1). 3. Using the J 45236-1 (2), install the front output shaft seal. 4. Remove the J 45236-1 and the J 4523-2. 5. Install the dust shield on the front output shaft. 6. Install the front propeller shaft. 7. Inspect the transfer case fluid level. 8. Install the fuel tank shield, if equipped. 9. Lower the vehicle. Refer to Vehicle Lifting. Locations Locations View Page 14247 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE Page 11751 Disclaimer Page 2915 ^ Drill Motor with 1/2 inch chuck, 11/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction. Note: Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot. The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN-45680-499) was sent in November, 2004 to affected Chevrolet and GMC dealers. The new pilot is white in color, and should be installed on EN-45680-411 Trim Tool Assembly. Buick and HUMMER dealers were sent EN-45680-400 Cylinder Liner Replacer kit with the correct pilot already installed. Inspect EN-45680-411 to ensure the correct white pilot is installed. Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition positive voltage. The SDM requests the IPC to flash the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and command the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store A Diagnostic Trouble code (DTC) and command the IPC to turn the AIR BAG indicator ON via class 2 serial data. The presence of a SIR system malfunction could result in non-deployment of the air bags or deployment in conditions less severe than intended. The AIR BAG indicator will remain ON until the malfunction has been repaired. Page 5343 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 2981 Bolt Extractor Tool Kit Part Number EN-47702 The bolt extractor kit EN-47702 provides the following components to assist in removal of the broken bolt segment: 1. One 5/32" reverse twist drill - part number EN-47702-6 2. One double-ended drill pilot insert - part number EN-47702-1 (ensures a straight drilling procedure) 3. Drill pilot inserts for larger diameter heads or main cap bolts - part number EN-47702-2 (ensure a straight drilling procedure) 4. Bolt extraction # 3 EZ out - part number EN-47702-3 (after the drilling procedure) 5. Bottom tap (M11 X 2) - part number EN-47702-5 (for the head bolts to chase the threads after the completion of bolt removal) 6. Bottom tap (M10 X 1.5) - part number EN-47702-4 (for the main bolts to chase the threads after the completion of bolt removal) Disclaimer Page 15684 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 10758 Conversion - English/Metric Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 15820 Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T79) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Position the left side second row seat in order to gain access to the bussed electrical center. 2. Remove the bussed electrical center protective covers. 3. Use the J 43244 in order to remove the fog lamp relay from the bussed electrical center. INSTALLATION PROCEDURE Page 13319 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 15225 Page 6021 Electrical Symbols Part 5 Interior - Cargo Cover Handle is Broken Cargo Cover: Customer Interest Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 8171 For vehicles repaired under warranty, use the table. Disclaimer Page 15923 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the 2 screws that retain the license lamp lens to the liftgate. 2. Remove the license lamp lens from the liftgate. 3. Remove the bulb (1) from the socket. INSTALLATION PROCEDURE Page 4232 Electrical Symbols Part 1 Page 5240 Various symbols are used in order to describe different service operations. Page 4840 Disclaimer Page 5077 Electrical Symbols Part 3 Page 7371 14. Install the drive axle. 15. Install the shock module and tighten the two upper retaining bolts. Tighten Tighten the bolts to 45 N.m (33 lb ft). 16. Tighten the lower shock module yoke to the lower control arm. Tighten Tighten the yoke to 110 N.m (81 lb ft). 17. Install the stabilizer shaft linkage. Tighten Tighten the stabilizer shaft linkage to 100 N.m (74 lb ft). 18. Install the knuckle assembly and the lower ball joint nut. Install the intermediate shaft through the knuckle assembly. Install the upper ball joint to the control arm and install the pinch bolt and nut. Tighten ^ Tighten the pinch bolt to 40 N.m (30 lb ft). ^ Tighten the lower ball joint nut to 110 N.m (81 lb ft). 19. Install the intermediate shaft nut. Tighten Tighten the nut to 140 N.m (103 lb ft). 20. Install the tie rod end in the steering knuckle. Tighten Tighten the tie rod end to 45 N.m (33 lb ft). 21. Install the brake caliper and brake hoses. Tighten Tighten the caliper bolts to 51 N.m (38 lb ft). 22. Install and connect the harness. 23. Inspect the fluid in the front differential housing. Add fluid as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Page 15411 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 9805 C700 Page 11095 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. Page 4083 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 13585 10. Install the auxiliary air conditioning duct to the vehicle with the bolt. Tighten the auxiliary air conditioning duct bolt to 10 N.m (88 lb in). 11. Connect the coax cable (1) to the navigation antenna, if equipped. 12. Connect the rain sensor electrical connector (2), if equipped. 13. Connect the inside rear view mirror electrical connector (3). 14. Install the windshield rearview mirror wire harness cover. 15. Install the video display. 16. If equipped, install the front and rear overhead console. 17. Install the windshield garnish moldings. 18. Install the center pillar trim panels. 19. Install the front side door sill plates. 20. Install the right sound insulator. 21. Connect the cellular antenna coax cable to the inner coupling on the left body side window. 22. Install the headliner harness to the left third pillar. 23. Install the headliner harness to the floor studs. 24. Install the ground terminals and the ground bolt to the left center pillar. Tighten the ground bolt to 10 N.m (88 lb in). Page 3839 Locations View Page 5388 1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2). 2. Connect the crankcase clean air hose to the valve cover port. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5). Tighten the bolts to 6 Nm (63 lb in). Page 3220 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10622 Locations View Page 1659 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 14496 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to DCM Programming/RPO Configuration. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. Page 1798 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2581 Refrigerant Oil: Fluid Type Specifications PAG (Polyalkaline Glycol) synthetic refrigerant oil (US GM part number 12345923) or equivalent. (Canadian GM part number 10953486). Page 11315 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 14774 Electrical Symbols Part 3 Page 3238 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 4408 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 11491 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - No. 1 Center Rear Trailblazer, Envoy and Bravada REMOVAL PROCEDURE 1. Remove the rear seat back assembly. 2. Remove the rear seat belt anchor nut from the seat belt buckle bracket. 3. Remove the rear seat back seat belt bezel by pressing in the buttons (1) on the plastic retainers. Page 13116 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. Installation Procedure 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer, Envoy, Bravada) Window Weatherstrip Run Channel Assembly Replacement - Rear (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. Page 4727 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - 1 The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. POWERTRAIN CONTROL MODULE (PCM) - 2 The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 4330 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 4096 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 8964 8. Remove the brake pad retaining clips from the mounting bracket, inboard brake pad shown. 9. Remove the brake caliper mounting bracket retaining bolts, lower bolt shown. 10. Remove the brake caliper mounting bracket. Page 12729 Parts are currently available from GMSPO. Disclaimer Lower Ball Joint Ball Joint: Specifications Lower Ball Joint Retaining Nuts 81 ft. lbs. Wear limit 0.125 inch Page 2627 Fuse Block - Underhood C2 Part 2 Page 1811 Equivalents - Decimal And Metric Part 1 Page 2535 Power Steering Fluid: Specifications GM Power Steering Fluid (GM P/N 1052884 - 1 pint, 1050017 - 1 quart, Canadian P/N 993294 - 1 pint, Canadian P/N 992648 - 1 quart or equivalent). Page 7763 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 5580 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 13609 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Door Sill Plate Replacement - Rear (TrailBlazer EXT, Envoy XL) Door Sill Plate Replacement - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Door Sill Plate Replacement - Lift Gate Door Sill Plate Replacement - Lift Gate Removal Procedure 1. Use a flat-bladed tool in order to release the 4 sill plate retaining tabs. Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: All Technical Service Bulletins Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 887 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Communication Module - Revised Service Procedure Central Control Module: Technical Service Bulletins Communication Module - Revised Service Procedure File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-012 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised Communication Interface Module Replacement Reconfiguration Procedure Models: 2002 Buick Century, LeSabre, Regal 2002 Cadillac DeVille, Seville 2002 Chevrolet Impala, Monte Carlo, TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Aurora, Bravada, Intrigue 2002 Pontiac Bonneville with Generation 4 On Star(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the Communication Interface Module Replacement procedure in the Cellular Communications sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 4 (formerly F1) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool. Important: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 1. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. 2. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 3. Use the ID information menu on the scan tool to access the new Station ID (STID) and the electronic serial number (ESN) and from the new VCIM. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VCIM and ask the advisor to perform the following procedure: 5. Add the new STID and the ESN to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 9131 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 1596 Electrical Symbols Part 5 Page 8404 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 13874 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 03-08-111-002G Date: 071221 Paint - Chips Behind Front Wheels/Front of Rear Wheels Front Axle Actuator Page 2931 20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line. 21. Using a light, illuminate the backside of the straight edge. 22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present of either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 24. Proceed to the next cylinder bore sleeve to be trimmed repeat steps 10-23 if necessary. Page 12498 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 12817 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 744862). 2. Remove the lower push-in retainer and the upper bolt from both the right and left front fascia pencil braces. 3. Remove the right and left front fascia pencil braces. 4. Replace the front fascia pencil braces with new pencil braces. Refer to the applicable part numbers listed below. 5. Install and "finger tighten" the upper brace bolts on both sides. 6. Install the lower brace push in retainers on both sides. Tighten Tighten the upper brace bolts to 10 N.m (89 lb in). 7. Lower the vehicle. Parts Information Parts are expected to be available 8-8-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 5091 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1652 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 4407 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 15609 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14946 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 9382 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the block base retaining nuts to the floor studs. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 14847 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15361 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 3078 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 3383 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The tender to radiator support rod will be removed as part of the radiator support cover. 1. Remove the radiator support cover. 2. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator. 3. Remove the air cleaner element (1) by grasping the filter and removing it from the air cleaner outlet duct (2) with a twisting and pulling motion. 4. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 1792 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 7048 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Page 8093 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 12363 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 9727 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Instruments - Odometer/Hour Meter Programming Procedure Odometer: Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 5948 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Instruments - Erratic Speedometer Operation Ground Strap: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Diagrams Throttle Body Page 10213 5. Loosen the jam nut (1) and remove the outer tie rod (2) from the inner tie rod (3). Do not reuse the jam nut. 6. Inspect the shaft for bent or damaged threads. 7. Clean the tapered surface of the steering knuckle. Installation Procedure 1. Lubricate the inner tie rod (3) threads with a suitable chassis lubricant before installing the outer tie rod (2). 2. Install the new jam nut (1) to the outer tie rod (2). 3. Install the outer tie rod (2) to the inner tie rod (3) 4. Install the outer tie rod to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the outer tie rod retaining nut. Page 2602 10. Remove the CPA from the LF side impact module yellow 2-way connector (2) located under the driver seat. 11. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. 12. Remove the CPA from the RF side impact module yellow 2-way connector (2) located under the passenger seat. 13. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 13734 Disclaimer Page 4097 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (1 or 2) and the bolt (3). Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 12916 2. Install the outside handle lock rods to the latch as previously noted. 3. Install the inside handle lock rods to the latch as previously noted. 4. Position the latch in order to connect the electrical connectors as needed. 5. Install the latch to the door. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the 3 screws that retain the latch to the door. Tighten the screws to 10 N.m (22 lb in). 7. Install the inside door handle. 8. Connect the lock cylinder rod to the cylinder, if equipped. 9. Install the lock rod to the outside door handle. 10. Connect the lock rod retaining clip to the outside door handle. 11. Install the water deflector. 12. Install the door trim panel. Page 3591 Electrical Symbols Part 3 A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 15951 1. Use the J 43244 in order to install the fog lamp relay to the bussed electrical center. 2. Install the protective covers to the bussed electrical center. 3. Reposition the left side second row seat. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 13528 Console: Service and Repair Bracket Replacement - Console Floor Bracket Replacement - Console Floor Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the floor shift control knob. 3. Remove the center console. Console Replacement 4. Disconnect the automatic transmission range selector cable. 5. Disconnect the electrical connector from the automatic transmission shift interlock solenoid. 6. Disconnect the electrical connector from the park brake. 7. Remove the console bracket from the vehicle, by removing the retaining nuts (1) from the center instrument panel (IP) bracket. 8. Remove the forward retaining screw, if equipped. 9. Remove the remaining fasteners from the console bracket. 10. Remove the console bracket from the vehicle. 11. Remove the floor shift control. Installation Procedure 1. Install the floor shift control. 2. Install the console bracket to the vehicle. 3. Loosely install all the fasteners that retain the console bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the retaining nuts (1) to the center IP bracket. Tighten nuts to 10 N.m (88 lb in). 5. Install the remaining fasteners that retain the console bracket to the vehicle. Tighten the nuts to 25 N.m (18 lb ft). 6. Connect the electrical connector to the park brake. 7. Connect the electrical connector to the automatic transmission shift interlock solenoid. 8. Connect the automatic transmission range selector cable. 9. Install the center console. Console Replacement 10. Install the floor shift control knob. 11. Remove the wheel blocks from the vehicle. Console Replacement Page 53 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 227 Specifications Brake Pedal Assy: Specifications Brake Pedal Pivot Bolt 19 ft. lbs. Brake Pedal Maximum Travel See Note Specification with 445 N (100 lbs) of force applied to the brake pedal, the ignition OFF, and the brake booster power reserve depleted. Page 15102 Oil Change Reminder Lamp: Service and Repair To reset the CHANGE ENG OIL light, do the following: 1. Turn the ignition key to run with the engine off. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat procedure. Locations Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 9214 Alternator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 14530 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Seat Switch Bezel Replacement REMOVAL PROCEDURE 1. Remove the 3 screws that retain the switch bezel to the seat. Page 2002 Fluid Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to valve body service and repair" Page 11424 13. Carefully remove the seat back cover from behind the trim edge of side impact air bag module. Important When separating the seat cover hook and loop retaining strip in the next step, do not pull the adhesive-backed strip from the pad. 14. Using a side-to-side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. 15. From the bottom of the seat back, place your hand up the front side of the seat back cover and release the hook and loop fasteners that attach the seat back cover to the foam pad. 16. Starting at the bottom of the seat back, remove the seat back cover by pulling the cover upwards. The bottom of the cover should be turning inside out as the cover rolls upwards. Important Do not remove the three hog rings that attach the cover to the foam pad. 17. Continue pulling the seat back cover upwards until the top of the seat belt retractor is accessible. 18. If equipped, disconnect the seat back heating element electrical connector. 19. Remove the two head restraint retainers from the top of the seat back. 20. Reposition the cover and pad as necessary. Page 793 Electrical Symbols Part 7 Page 14981 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 11670 Electrical Symbols Part 5 Page 12210 1. Attach the radio antenna module to the headliner retaining strips. 2. Connect the coax cable to the radio antenna module. 3. Connect the electrical connector to the radio antenna module. 4. Connect the radio antenna module electrical connector to the stationary glass. 5. Install the rear headliner to roof retainers. 6. Install the left coat hook. Page 8888 7. Remove the rear brake caliper from the brake caliper mounting bracket. Installation Procedure 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the rear brake caliper assembly to the mounting bracket. Page 13972 Equivalents - Decimal And Metric Part 1 Page 3917 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1522 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 7796 Page 5882 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 8273 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 3453 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 14951 Various symbols are used in order to describe different service operations. Page 14547 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Page 4308 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 917 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4307 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Diagrams Trailer Connector: Diagrams Trailer Connector Part 2 Trailer Connector Part 1 Page 7067 Page 11843 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 2735 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Communication Module - Revised Service Procedure Central Control Module: Technical Service Bulletins Communication Module - Revised Service Procedure File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-012 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised Communication Interface Module Replacement Reconfiguration Procedure Models: 2002 Buick Century, LeSabre, Regal 2002 Cadillac DeVille, Seville 2002 Chevrolet Impala, Monte Carlo, TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Aurora, Bravada, Intrigue 2002 Pontiac Bonneville with Generation 4 On Star(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the Communication Interface Module Replacement procedure in the Cellular Communications sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 4 (formerly F1) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool. Important: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 1. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. 2. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 3. Use the ID information menu on the scan tool to access the new Station ID (STID) and the electronic serial number (ESN) and from the new VCIM. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VCIM and ask the advisor to perform the following procedure: 5. Add the new STID and the ESN to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 1033 Page 11701 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) The Driver Information Center (DIC) consists of a single line 22 character Vacuum Fluorescent (VF) display placed in the lower center area of the Instrument Panel Cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver, The display parameters are cycled, changed, and acknowledged using four (4) DIC buttons. ^ Trip Information Button representation icon appears as a road to the horizon. ^ Fuel Information Button representation icon appears as a gasoline pump. ^ Personalization Button representation icon appears as a human next to vehicle. ^ Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest): ^ Service Diagnostics ^ Driver Identifier ^ Feature Programming ^ Driver Warnings ^ Vehicle Information Vehicle Information Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC Trip Information/Reset Capabilities The available DIC Trip Information and reset capabilities are as follows: ^ Odometer - Cannot be reset ^ Trip Odometer A - Can be reset ^ Trip Odometer B - Can be reset ^ Timer - Can be reset Trip Reset Stem The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the reset stem or SWC Select button is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: ^ Odometer ^ Trip A odometer ^ Trip B odometer 2. Holding the reset stem for greater than 3 seconds or depressing the SWC Select button while either Trip A or Trip B odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip odometer parameter is being displayed, pressing the DIC Trip Information button will display the next trip odometer parameter. 4. If the next Trip Information parameter to be displayed is Timer or blank, pressing the reset stem will return the display to the Odometer. Odometer The odometer is capable of displaying values from 0 to 999,999 MI or KM. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. Trip Odometers The DIC can display Trip A or Trip B odometers. The trip odometers are capable of displaying values from 0 to 9999.9 MI or KM. When the maximum value is reached, the trip odometer will roll over to 0.0. Timer The Timer is displayed as XX (hours): XX (minutes): XX (seconds). The Timer is started and stopped using the DIC Select button. Page 4852 Disclaimer Page 4734 Engine Control Module: Service and Repair Service Programming System (SPS) SERVICE PROGRAMMING SYSTEM (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: The Vehicle Identification Number (VIN) - The crankshaft variation learned position - The software/calibrations identification numbers - The control module security information - Flash Read Only Memory - Flash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. SERVICE PROGRAMMING METHODS The 4 methods of programming a control module and the proper tools for each method are as follows: Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle - Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. - Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle - Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle. BEFORE PROGRAMMING B CONTROL MODULE IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. - General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. - Heating, Ventilation, And Air Conditioning (HVAC) systems - Engine Cooling fans, etc. - The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. - All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA - DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Page 3859 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 409 Various symbols are used in order to describe different service operations. Locations Data Link Connector: Locations Locations View Page 13873 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 9589 32. Reposition the rear electrical center through the carpet and reposition the carpet. 33. Reinstall the rear electrical center bracket and tighten. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 34. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 35. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in order, proceed to the next step. Otherwise, check your work. 36. Turn the key OFF. Remove the key. 37. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 38. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 39. Reinstall the rear electrical center cover. 40. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the attaching screws. 41. Reinstall the knee bolster (TrailBlazer). 42. Reinstall the left side closeout/insulator panel (TrailBlazer). 43. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 44. Reinstall the console to the vehicle and install the retainers. 45. Reinstall the shift boot and handle assembly. 46. Reinstall the console bin and retainers. 47. Reinstall the first lock pillar trim and carpet retainers to both door openings. 48. Position the driver's seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 49. Reinstall the SIR fuse # 18 in the underhood rear electrical center and close the hood. 50. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios Without Rear Audio Controls These vehicles use wiring harness P/N 15164934. 1. Remove the key from the lock cylinder. Page 4206 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 7867 Case Adapter: Service and Repair Transfer Case Adapter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case assembly from the vehicle. Important: The transmission mount DOES NOT have to be removed to perform the following service procedure. 3. Remove the transmission mount bolts. 4. Install a transmission jack under the transmission. 5. Lift the transmission just high enough to remove the transfer case adapter. Interior - Console Power Outlet Cover/Seat Interference Auxiliary Power Outlet: Customer Interest Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 15367 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 177 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 14690 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 14651 Front Door Window Glass Weatherstrip: Service and Repair Window Weatherstrip Run Channel Assembly Replacement - Front REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten Tighten the retaining bolts to 10 N.m (88 lb in). Page 3234 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 5640 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Filter to Tank REMOVAL PROCEDURE CAUTION: ^ Refer to Fuel and EVAP Pipe Caution in Service Precautions. ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Remove the fuel tank. 2. Disconnect the fuel feed pipe from the fuel sender assembly (4). 3. Disconnect the fuel feed pipe from the fuel filter (7). 4. Disconnect the fuel return pipe from the fuel sender assembly (4). 5. Disengage the fuel pipe clip (6) at the front of the fuel tank. 6. Remove the fuel pipes. INSTALLATION PROCEDURE 1. Connect the fuel return pipe to the fuel sender assembly (4). 2. Connect the fuel feed pipe to the fuel filter (7). 3. Connect the fuel feed pipe to the fuel sender assembly (4). 4. Install the fuel pipe clip (6) to the fuel pipes at the front of the fuel tank. 5. Install the fuel tank. Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the left coat hook. NOTE: In order to avoid damaging the antenna lead connector, follow these guidelines: Use a plastic tool and carefully pry the connector from the window. - Do NOT pull on the connector, which may be stuck to the urethane adhesive or the headliner. 2. Disconnect the radio antenna module electrical connector from the stationary glass. 3. Release the rear headliner to roof retainers. 4. Lower the rear of the headliner far enough to access the radio antenna module located on the left side of the vehicle. 5. Disconnect the electrical connector from the radio antenna module. 6. Disconnect the coax cable from the radio antenna module. 7. Remove the radio antenna module from the headliner retaining strips. 8. Remove the radio antenna module from the vehicle. INSTALLATION PROCEDURE Seat Cushion Latch Release Assembly Replacement Rear No. 1 Seat Latch: Service and Repair Seat Cushion Latch Release Assembly Replacement - Rear No. 1 REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). 4. Remove the 3 bolts securing the rear seat cushion latch to the seat pan. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 11947 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 10126 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2302 Disclaimer Page 10272 7. Remove the shock module yoke lower mounting nut. 8. Disconnect the shock module yoke from the lower control arm using J24319-B. 9. Remove the lower control arm to lower control arm bracket mounting nuts. Important: Note the direction the bolts are removed for installation. 10. Remove the lower control arm to lower control arm bracket mounting bolts. Locations OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 15900 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 114 Page 9640 Fuse Block: Locations Fuse Block - Underhood Fuse Block Underhood Locations View Located in the underhood compartment above the left front wheel well. Page 5741 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 3335 During the 2004 model year, there was a design change made to the engine oil pick up tube and the front cover as shown. The first design parts used in production for 2002, 2003 and part of 2004 model year used an 0-ring type seal between the pick up tube and the front cover. The second design parts began production during the 2004 model year and use a face type seal. Anytime the front cover or oil pick up tube are being serviced, be sure to identify which design is being serviced. The correct pick up tube must be used with its corresponding front cover or an engine failure could result. Any vehicle requiring a new front cover must be serviced with the second design front cover, therefore, the engine oil pick up tube must be replaced at the same time. Disclaimer Page 2275 Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 4490 Spark Plug: Service and Repair Spark Plug Replacement Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 11040 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 11577 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Page 5998 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 7438 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 10851 HVAC Control Module - Auxiliary (Body Type VIN 6) Locations Sunroof / Moonroof Module: Locations Locations View Page 15343 Electrical Symbols Part 4 Page 12872 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Page 14845 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 4988 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 2716 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 1746 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 1460 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 1904 10. Disconnect the discriminating sensor (2) electrical connector. 11. Remove the discriminating sensor from the vehicle. INSTALLATION PROCEDURE 1. Position the discriminating sensor assembly above the front bumper. 2. Connect the discriminating sensor (2) electrical connector. 3. Install the connector-position assurance (CPA) to the discriminating sensor electrical connector. 4. Install the retaining bolts and protective cover (1) to the discriminating sensor. 5. Position the discriminating sensor assembly to the frame (1). NOTE: Refer to Fastener Notice in Service Precautions. Page 1638 Electrical Symbols Part 2 Page 4071 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 13084 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. SIR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SIR Service Precautions CAUTION: ^ Refer to SIR Special Tool Caution in Service Precautions. ^ If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause SIR deployment and result in personal injury. The moisture must be removed and any damage caused by the moisture must be repaired prior to SIR component replacements. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming. Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe these guidelines could result in Restraint Systems deployment, personal injury, or unnecessary SIR system repairs. ^ When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Air Bag(s) Arming and Disarming. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side Impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. SIR Service Precautions The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: ^ Do not expose inflator modules to temperatures above 65°C (150°F). ^ Verify the correct replacement part number. Do not substitute a component from a different vehicle. ^ Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater: ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint IP module disable switch ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact modules ^ Inflatable restraint side impact sensors (SIS) ^ Inflatable restraint steering wheel module ^ Inflatable restraint steering wheel module coil Page 15070 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 14393 13. Install the rear seat belt anchor bolt into the seat belt buckle bracket. Tighten Tighten the rear seat belt anchor bolt to 55 N.m (41 lb ft). 14. Install the seat belt buckle bracket, on the right side only. 15. Install the seat back into the vehicle. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the head restraint. 2. Press in the buttons (1) on the plastic retainers. 3. Remove the seat belt bezel from the top of the seat back by removing the plastic retainers and sliding the bezel off of the seat belt. 4. Remove the three screws securing the inboard rear seat back hinge cover. Page 14255 Seat Horizontal Motor - Driver/Passenger Page 11904 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 1882 Equivalents - Decimal And Metric Part 1 Page 8880 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul- Front ^ Tools Required J 8092 Driver Handle - J 43885 Boot Seal Installer Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure Page 3624 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 12611 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 11225 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. INSTALLATION PROCEDURE Page 1694 Electrical Symbols Part 1 Page 7025 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 4018 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 9599 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 6173 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 2876 7. Remove the camshafts. Installation Procedure 1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil. 2. Install the intake and exhaust camshafts to their original positions. 3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Install the camshaft caps onto their original locations. The camshaft caps are pin stamped for direction and numerical order. Page 10687 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, LH REMOVAL PROCEDURE 1. Remove the LH lower closeout/insulator panel. 2. Remove the push pin (2) retaining the floor air outlet duct (1) to the heater module. 3. Remove the floor duct (1). INSTALLATION PROCEDURE 1. Install the floor air outlet duct (1) into position. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the floor air outlet duct retaining push pin (2). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the LH lower closeout/insulator panel. Page 4402 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Page 4010 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 8039 Page 745 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 13258 1. Position the latch/lock assembly to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the latch/lock assembly to the liftgate. Tighten the screws to 10 N.m (89 lb in). 3. Connect the lock cylinder bellcrank rod (1) to the latch/lock assembly. 4. Connect the electrical connector to the latch/lock assembly. 5. Position the bellcrank to the latch/lock assembly. 6. Install the screws that retain the bellcrank to the latch/lock assembly. Tighten the screws to 0.7 N.m (6 lb in). 7. Connect the bellcrank rod to the latch/lock assembly. 8. Connect the outside handle rod to the bellcrank. 9. Install the liftgate trim panel. 10. Install the liftgate window garnish molding. Page 483 Endgate Module (EGM) C2 (XUV) Part 2 Page 2310 1. Install the air cleaner element (1) onto the air cleaner outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element and air cleaner outlet duct into the lower air cleaner housing/washer solvent tank assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the air cleaner cover/resonator assembly (1). Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator support cover. Page 4403 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 6284 Disclaimer Diagrams Seat Belt Switch - Driver Page 5917 Ignition Coil 5 Ignition Coil 6 Page 8831 Electrical Symbols Part 6 Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 14256 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Page 12557 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 5167 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3974 Equivalents - Decimal And Metric Part 1 Page 7072 Page 14627 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 12661 Electrical Symbols Part 3 Page 12215 Disclaimer Page 6101 Electrical Symbols Part 5 Page 15273 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 14367 13. Install the rear seat belt anchor bolt into the seat belt buckle bracket. Tighten Tighten the rear seat belt anchor bolt to 55 N.m (41 lb ft). 14. Install the seat belt buckle bracket, on the right side only. 15. Install the seat back into the vehicle. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the head restraint. 2. Press in the buttons (1) on the plastic retainers. 3. Remove the seat belt bezel from the top of the seat back by removing the plastic retainers and sliding the bezel off of the seat belt. 4. Remove the three screws securing the inboard rear seat back hinge cover. Page 9465 C305 For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes GM Oil Life System (TM) - Resetting Maintenance Reminder Control Module: Technical Service Bulletins GM Oil Life System (TM) Resetting File In Section: 00 - General Information Bulletin No.: 02-00-90-001 Date: March, 2002 INFORMATION Subject: GM Oil Life System(TM) - Resetting Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada These vehicles have an oil life monitor. The GM Oil Life System(TM) will show when to change the engine oil and oil filter. The GM Oil Life System(TM) must be reset after changing the engine oil and oil filter. Resetting Procedure The current Owner's Manual contains the following reset procedure: 1. Turn the ignition to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. However, it has been found that after completing the reset procedure, the CHANGE ENG OIL light does not flash as stated in the vehicle Owner's Manual. If the CHANGE ENG OIL light goes out after the reset procedure and does not return after the next ignition cycle, then the system has been reset. If the vehicle is equipped with a Driver Information Center (DIC), then reset confirmation can also be done by verifying that the Engine Oil Life percentage value has reset to 100%. Use the above information to prevent the inadvertent replacement of the instrument cluster if there are comments that the oil life reset feature does not work. Disclaimer Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 13530 Console Storage Bin Replacement Removal Procedure 1. Open the storage bin cover. 2. Remove the 6 screws that retain the storage bin to the console. 3. Remove the storage bin from the console. Installation Procedure 1. Install the storage bin to the console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 6 screws that retain the storage bin to the console. Tighten the screws to 2.5 N.m (22 lb in). 3. Close the storage bin cover. Overhead Console Replacement - Front Overhead Console Replacement - Front Removal Procedure 1. Remove the 2 screws that retain the console to the roof panel. 2. Release the front retaining tabs. 3. Lower the console and disconnect the electrical connectors as needed. 4. Remove the console from the vehicle 5. If replacing the console, remove the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. If replacing the console, remove the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 7. If replacing the console, remove the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 8. If replacing the console, remove the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 9. If replacing the console, remove the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Page 14936 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 4744 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The FTP sensor mounts in the top of the fuel tank-sending unit. The PCM provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the PCM that can vary between 0.1-4.9 volts. As fuel tank pressure increases, FTP sensor voltage decreases (high pressure = low voltage). As fuel tank pressure decreases, FTP voltage increases (low pressure or vacuum = high voltage). Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 696 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Page 159 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 6004 Conversion - English/Metric Page 7382 1. In the illustration shown number 1 is Chevrolet and GMC and number 2 is an Oldsmobile. The affected seals are indicated by the arrows. Remove the brake caliper retaining bolts from the bracket and the brake hose from knuckle assembly. 2. Disconnect the ABS harness connector and remove the harness. 3. Support the brake caliper assembly. 4. Remove the outer tie rod retaining nut and tie rod from the knuckle assembly using the J 24319 Steering Linkage and Tie Rod Puller. 5. Remove the intermediate shaft nut and loosen the shaft from the knuckle assembly. 6. Remove the upper ball joint pinch bolt and lower ball joint nut and remove the knuckle assembly. 7. Remove the drive axle from the housing by placing a brass drift punch against the tripot housing and striking it with a hammer. 8. Remove the stabilizer bar linkage. 9. Remove the upper strut retaining bolts. 10. Remove the nut from the lower strut assembly and use the J 24319-B to press the lower strut assembly off of the stud, and remove the assembly from the vehicle. 11. Remove the outboard intermediate shaft seal or the differential carrier seal using the J 29369-2 - Bushing and Bearing Remover and the J 6125-B - Slide Hammer. 12. Clean the intermediate shaft bearing assembly and/or the differential housing of oil and dirt. Install the seal using the J 45225 - Seal Installer and the J 8092 - Shaft Installer. 13. Clean and inspect the intermediate shaft for dirt or rust. Page 11927 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 8844 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5061 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 15881 Horn Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the horn relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the horn relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. Page 14371 6. Install the cover side flaps to the frame with the two push pins (1) from each side of the seat back. 7. Install the J-strips (2) on the bottom of the seat back cover (1). NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the rear seat belt (1) to the seat with the rear seat belt anchor nut (2). Tighten Tighten the rear seat belt anchor nut to 55 N.m (41 lb ft). Page 1612 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 14765 Conversion - English/Metric Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. Page 4145 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 10845 Locations View - HVAC Systems - Automatic Page 13508 13. Position the outlet in the retainer ring and partially push the outlet in. 14. Through the controller unit opening, connect the electrical connector to the back of the outlet. 15. Press in the rest of the outlet until fully seated. 16. Install the auxiliary audio/heater controller unit back into place. 17. Install the AUX PWR 1 Fuse 46 (20 amp) into the rear fuse block. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Fuse Block - Rear (Long Wheelbase) Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 11453 Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 1419 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 399 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft Coupler: All Technical Service Bulletins Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 1466 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 8235 3. Install the rear propeller shaft. 4. Inspect the transfer case fluid level. 5. Lower the vehicle. Refer to Vehicle Lifting. Page 11202 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection ^ Vehicles involved in accidents resulting in frame damage, major body or sheet metal damage, or where the steering column has been impacted, or where supplemental inflatable restraint systems deployed may also have a damaged or misaligned steering column. ^ Check the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. ^ Observe how the bracket is attached to the jacket assembly. ^ If the capsules are not securely seated and the bracket is bolted to the jacket assembly, replace only the bracket. ^ If the capsules are not securely seated and the bracket is welded to the jacket assembly, replace only the jacket assembly. ^ Check for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. Replace the jacket assembly if the measured dimensions are not within specifications. ^ Check for tab (1) breakage on the bearing and adapter assembly. Page 12227 Page 12530 Page 141 Page 12806 Parts Information Parts are expected to be available 8-8-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Page 6949 7. Install the new retaining ring (E-clip) into the remaining quick connect fittings. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 8. Connect the rear cooler lines (2) to the front cooler lines (1). 9. Install the cooler lines into the quick connect fitting. 10. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 11. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 12. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Body - BCM Delayed Locking Feature Explanation Body Control Module: All Technical Service Bulletins Body - BCM Delayed Locking Feature Explanation File In Section: 08 - Body and Accessories Bulletin No.: 03-08-64-014 Date: April, 2003 INFORMATION Subject: Door Locks Delayed Locking Feature Added with Body Control Module (BCM) Replacement Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Customers who have had the body control module (BCM) replaced may notice a change in how their door locks function. The delayed locking feature was not available for 2002 models. However, after replacing the BCM with P/N 150652g3, the system will function as designed for the 2003 model year, which has the delayed locking feature. This feature may be turned on as the default position when the new BCM is programmed and installed. The delayed locking feature operates with a chime sound when the customer attempts to lock the vehicle with the driver's door open. This will occur the first time the door lock button or remote keyless entry is depressed. The doors will not lock for 5 seconds after the last door is closed. Because delayed locking was not available in 2002, there is no explanation of this feature in the Owner's Manual. When a BCM (PIN 15065293) is replaced in any of the above vehicles, please provide the customer with a copy of page 2-9 from a 2003 Owners Manual (SI Document ID # 878793). Disclaimer Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 5832 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 5551 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the air cleaner outlet resonator. 3. Disconnect the engine wiring harness from the retaining clips at the front of the engine. 4. Disconnect the fuel pressure regulator vacuum line. 5. Clean any dirt from the fuel pressure regulator and the surrounding area. 6. Disconnect the fuel return pipe. 7. Remove the fuel return pipe retainer. 8. Remove the fuel pressure regulator retainer. 9. Remove the fuel pressure regulator. 10. Inspect the regulator filter screen for contamination. If contaminated, replace the fuel pressure regulator. INSTALLATION PROCEDURE 1. Install the regulator filter. 2. Install the new O-ring on the fuel pressure regulator. 3. Lubricate the fuel pressure regulator O-ring with clean engine oil. 4. Push the fuel pressure regulator into the regulator housing on the fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the fuel pressure regulator retainer. Tighten Tighten the regulator retainer screw to 8 N.m (71 lb in). Page 5450 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop Fuel Injector Pressure Drop If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly. Pressure Drop 1.5 psi Fuel Injector Balance Test Example (Typical) Page 11214 8. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 9. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 10. Install the AIR BAG Fuse to the fuse block. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 5130 Intake Air Temperature (IAT) Sensor Locations Locations View Page 15714 Cornering Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10665 1. Install the mode actuator. 2. Connect the electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the mode actuator. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the air outlet duct to the console. 5. Install the screw to the air outlet duct. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the console. Re-Calibrating Actuators (Auxiliary HVAC) When replacing the auxiliary HVAC control module it will be necessary to allow the auxiliary HVAC control module to perform a re-calibration process. When installing the auxiliary HVAC control module be sure to perform the following: 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the auxiliary HVAC control module. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. Wait 40 seconds for the auxiliary HVAC control module to re-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing an auxiliary HVAC actuator it will be necessary to allow the auxiliary HVAC control module to perform a re-calibration process. When installing the auxiliary HVAC actuator be sure to perform one of the following: Preferred Method (W/Scan Tool) 1. Clear all DTCs 2. Place the ignition switch in the OFF position. 3. Install the auxiliary HVAC actuator. 4. Re-connect all previously disconnected components. 5. Place the ignition switch in the RUN position. 6. With the scan tool, initiate the HVAC Actuator Recal. feature of the RHVAC/RSA module Special Functions menu. 7. Verify that no DTCs have set as current DTCs. Alternate Method (W/O Scan Tool) 1. Clear all DTCs 2. Place the ignition switch to the OFF position. 3. Disconnect the scan tool. 4. Install the auxiliary HVAC actuator. 5. Re-connect all previously disconnected components. Page 3938 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 8842 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 473 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE Page 4927 INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. Page 4352 Conversion - English/Metric Page 2992 13. Remove the camshaft cover. 14. Clean and inspect the camshaft cover. Installation Procedure 1. Install a new camshaft cover seal. 2. install new rubber ignition control module seals. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the camshaft cover arid secure with the cam cover bolts. ^ Tighten the camshaft cover bolts to 10 Nm (89 inch lbs.). 4. Install the ignition control modules and secure the modules with bolts. ^ Tighten the ignition coil bolts to 10 Nm (89 inch lbs.). 5. Connect the ignition control module electrical connectors. Page 11854 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 4254 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 4400 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 2008 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 10390 Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Revised Shock Module Replacement Bulletin No.: 06-03-08-011 Date: August 28, 2006 SERVICE MANUAL UPDATE Subject: Revised Shock Module Replacement Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer Models 2002-2007 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X This bulletin is being issued to revise the Shock Module Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The recommended tool to use is J 36607 instead of J 24319-B. Shock Module Replacement Tools Required J 36607 Ball Joint Separator Removal Procedure Remove the shock module upper retaining nuts. Page 1141 OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Audio System - Poor Radio Reception/Station Drifting Antenna Cable: Customer Interest Audio System - Poor Radio Reception/Station Drifting Bulletin No.: 05-08-44-016A Date: March 15, 2006 TECHNICAL Subject: Poor Radio Reception or Radio Will Not Stay On Station (Check Antenna Coax Cable Connection and/or Install Antenna Cable Extension) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2004-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2006 GMC Envoy Denali, Envoy Denali XL 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Attention: Vehicles built after December 21, 2004 were produced with the radio antenna extension cable already installed. Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add models and provide another cause for the condition. Please discard Corporate Bulletin Number 05-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on poor radio reception or that the radio will not hold the station. This occurs on either AM or FM bands. Cause The antenna coax cable connection behind the glove box door may not be fully seated or incorrect radio coax impedance. Correction Inspect the antenna coax cable connection and/or install an antenna extension cable, P/N 15267997, using the following procedure. 1. Remove the right closeout/insulator panel from the IP. 2. Verify that the antenna coax cable connection leads are fully seated. 3. If the leads are fully seated, separate the connection and install an antenna extension cable, P/N 15267997, between the two leads. 4. Install the right closeout/insulator panel to the IP. Parts Information Warranty Information (excluding Saab U.S. Models) Page 4926 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, remove the BCM (1) from the rear electrical center. Page 406 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 14784 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Campaign - Instrument Cluster Software Update Technical Service Bulletin # 03013 Date: 080522 Campaign - Instrument Cluster Software Update # 03013: Customer Satisfaction - Instrument Panel Cluster Gauges Inoperative - (May 22, 2003) Subject: 03013 - Instrument Panel Cluster Gauges Inoperative Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition General Motors has decided that certain 2002 model year Chevrolet TrailBlazer and TrailBlazer EXT; GMC Envoy and Envoy XL; and Oldsmobile Bravada vehicles may have an intermittent condition at vehicle start-up in which the instrument panel cluster may not power up, resulting in most of the displays, telltale lights, and functions being inoperative. Correction Dealers are to reprogram the instrument panel cluster software. Vehicles Involved Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure Some vehicles involved in this customer satisfaction program may have had their instrument panel cluster (IPC) replaced prior to this program. As a result, the replacement cluster may not need to be reprogrammed. To determine whether the IPC in the vehicle requires reprogramming, the following procedure must be performed. Important: The Tech 2 diagnostic tool must be updated with software version 8.0, released July 2002, or newer, in order to perform the reprogramming. 1. Connect the Tech 2 to the vehicle's data link connector (DLC) located under the instrument panel to the right of the steering column. Diagrams Engine Oil Level And Temperature Sensor Page 14135 Sunroof / Moonroof Motor: Service and Repair POWER SUNROOF MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (Trailblazer EXT, Envoy XL) or Headliner Replacement (Trailblazer, Envoy, Bravada) in Interior Trim. 2. Remove the tie strap that retains the white connector to the drive cable tube sunroof motor wiring harness. 3. Disconnect the sunroof motor wiring harness electrical connector. 4. Remove the screws (1) which retain the sunroof motor (2) to the sunroof assembly. 5. Remove the sunroof motor (2) from the sunroof assembly. INSTALLATION PROCEDURE 1. Align the splines on the sunroof motor shaft with the drive gear on the sunroof assembly. 2. Install the sunroof motor (2) to the mounting bracket, ensuring that the sunroof motor is fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws (1) that retain the sunroof motor (2) to the mounting bracket. Tighten Tighten the sunroof motor screws to 3 N.m (27 lb in). 4. Connect the sunroof motor wiring harness electrical connector. 5. Install the tie strap retaining the sunroof motor wiring harness. 6. Install the headliner. Page 13567 50. Remove the bolt securing the auxiliary air conditioning duct to the vehicle. 51. Remove the 2 push pins (2, 3) from the rear of the headliner. 52. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 53. With the aid of an assistant, lower the headliner to release the interlocking strips (1) that retain the headliner to the roof panel. 54. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 55. With the aid of an assistant, remove the headliner from the vehicle. Page 264 Page 9475 C101 Part 1 Page 2928 ^ EN 45680-412 Set Gage Ring (2) ^ EN 45680-413 Metal Shavings Catch Plug (3) ^ EN 45680-866 Drive Adapter (4) ^ EN 45680-414 Bolts (5) 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. 2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves. 4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Page 8160 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Page 1299 Locations Locations View Page 15603 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 6986 Page 10379 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Page 8537 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Important: Due to limited parts availability as well as the cost and size of parts, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the results of the "clean neutral" test determines that it is necessary to replace the transfer case. Important: It is estimated that less than 1% of involved vehicles will require a transfer case replacement. Most dealers will not replace a single transfer case as part of this recall. Dealers should call the Technical Assistance Center to obtain the transfer case replacement. (U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5 or later versions; and on TIS 2000 # 10 CD-ROM or later releases. The table shows the calibration information. (Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer. Notice: Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into the control module via a Techline tool device. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number 5-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Page 13521 Console: Specifications Fastener Tightening Specifications Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Transfer Case Actuator: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 3866 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Recall - Front Seat Belt Retractor Defect Technical Service Bulletin # 04037 Date: 040601 Recall - Front Seat Belt Retractor Defect File In Section: Product Recalls Bulletin No.: 04037 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: FRONT SEAT BELT RETRACTOR NONCOMPLIANCE MODELS: 2002 CHEVROLET TRAILBLAZER 2002 GMC ENVOY 2002 OLDSMOBILE BRAVADA Since the inspection procedure in this recall can be performed quickly and easily, and to reduce the inconvenience to the customer, when a customer brings their vehicle into your dealership for this recall, if at all possible, have this inspection performed on the vehicle immediately so that the customer does not have to leave their vehicle at the dealership. If you confirm proper retractor lockup, GM recommends that you demonstrate to the customer that the retractor locks properly. CONDITION General Motors has decided that certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies. These vehicles have a condition where one of the two sensors in the driver's and front passenger's seat belt retractors may be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as during heavy braking, may not operate as intended. If this were to occur, the seat belt may not restrain the occupant as intended during a crash, and could result in injury to the occupant. CORRECTION Dealers are to inspect the driver and front passenger seat belt retractors, and replace them if necessary. Since the inspection is easy to perform, and to reduce customer inconvenience, customers will be sent an inspection procedure with instructions to contact their dealer if a seat belt retractor does not lock while performing the inspection. However, if they desire, they can take their vehicle to their dealer for the inspection. VEHICLES INVOLVED Involved are certain 2002 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Page 4722 Conversion - English/Metric Page 415 Front Passenger Door Module (FPDM) C1 Page 11961 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 6112 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 5938 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8041 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Page 5471 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 12548 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 4859 Electrical Symbols Part 3 Page 9378 Fuse Block - Rear (Long Wheelbase, Body Type VIN 6) Page 4065 Electrical Symbols Part 6 Page 5821 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 8232 6. Pry the front out shaft seal from the transfer case. 7. Remove the front output shaft seal from the transfer case. Installation Procedure 1. Install the J 45236 on the front output shaft. Page 6632 Disclaimer Page 11965 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 13949 Electrical Symbols Part 8 Page 5058 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 3928 Various symbols are used in order to describe different service operations. Page 7406 Important: Ensure that the rings are fully seated. 15. Install the spacer ring (2) and spider assembly (1) onto the halfshaft bar (3). 16. Install the other spacer ring in the groove at the end of the halfshaft bar. Ensure that the rings are fully seated. 17. Pack the boot and housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 18. Place the large retaining clamp (2) on the boot. 19. Place the housing (1) and the new trilobal tripot bushing over the spider assembly (3). 20. Install the boot onto the trilobal tripot bushing. 21. Check the inboard stroke position (see diagram). ^ For male tripot housing assembly: dimension a = 280 mm (11 inch) ^ For female tripot housing assembly: dimension b = 228 mm (9 inch) Page 4259 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 7085 Shifter A/T: Service and Repair Floor Shift Control Knob Replacement Floor Shift Control Knob Replacement Removal Procedure 1. The floor shift control knob and boot are serviced as an assembly. 2. Loosen the set screw (3) or (1) for Oldsmobile models. 3. Push in at the base of the boot to release the locking tabs (2) from the console assembly. 4. Pull up to remove the knob and boot assembly from the transmission control (4). Installation Procedure 1. Install the knob and boot assembly onto the transmission control (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Engage the locking tabs (2) with the console assembly. ^ Tighten the control knob set screw (1 or 3) to 2 Nm (18 inch lbs.). A/T - Oil Cooler Flushing/Flow Check Procedures Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 381 Electrical Symbols Part 5 Page 987 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 3847 Electrical Symbols Part 6 Page 4481 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 630 High Beam Relay: Service and Repair TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood fuse block. 3. Use the J 43244 in order to remove the high beam relay (1) from the underhood fuse block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the high beam relay (1) to the underhood fuse block. 2. Install the protective covers to the underhood fuse block. 3. Close the hood. A/C - Slow to Cool in Hot/Humid Conditions Fan Clutch: Customer Interest A/C - Slow to Cool in Hot/Humid Conditions Bulletin No.: 04-01-38-019A Date: June 07, 2005 TECHNICAL Subject: Intermittent Slow to Cool HVAC Performance Concerns in High Ambient Temperatures and/or High Humidity Conditions After Start Up, Especially at Low Engine Speeds (Install New Engine Cooling Fan Clutch) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005 Saab 9-7X Supercede: This bulletin is being revised to provide repair information for this customer concern. Please discard Corporate Bulletin Number 04-01-38-019 (Section 01 - HVAC). Condition Some customers may comment on slow to cool Air Conditioning (A/C) performance or high A/C outlet temperatures after start up or that the A/C system is not cooling sufficiently, especially in high ambient temperatures. This may be an intermittent condition and the performance of the Heating, Ventilation and Air Conditioning (HVAC) system may not meet customer expectations. Cause This condition may be caused by the response of the Electro-Viscous (EV) fan clutch and can be related to airflow across the condenser. This low A/C system performance can occur for longer periods of time if the vehicle is allowed to idle or is driven in low speed conditions. The response of the EV fan clutch will affect A/C system performance. As higher road speeds are attained, the increased airflow across the condenser will usually improve A/C system performance and the response of the EV fan clutch. This condition may be more evident after the vehicle has set for a period of time and can be difficult to duplicate. The condition may occur after the vehicle has set for as little as 10 minutes or as long as overnight. It is most prevalent intermittently during the first 15 minutes of operation. Correction Technicians are to replace the EV fan clutch with a new design part, P/N 15293048, on vehicles built before June 2005. Vehicles built in June 2005 may already have the updated EV fan clutch and it will not need to be replaced. For 2004 model year vehicles and older, update the Powertrain Control Module (PCM) with a software calibration that was developed to improve coolant temperature gauge readings. This new calibration will cause the PCM to command small amounts of additional fan engagement to better control engine coolant temperatures. Model year 2005 vehicles already have this calibration installed. Refer to Corporate Service Bulletin Number 04-06-02-005 for more information about this calibration. Proper diagnosis of any customer concern is essential. Refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure in SI to begin a diagnosis of any HVAC concerns. Refer to the Diagnostic Starting Point-Engine Cooling procedure in SI to begin a diagnosis of any engine cooling or engine cooling fan concerns. If an attempt is made to diagnose an HVAC system concern, all parameters must be measured. As an example, both the low and high side refrigerant pressure readings must be measured. If only the low side pressure readings were measured, it would appear that the A/C compressor is disengaging at a higher pressure than expected. If both the low and high side pressures were being measured, it would be noted that the A/C compressor is probably disengaging due to the maximum high side pressure cut out point being reached. This occurs to protect the HVAC system from damage. The updated PCM software calibration along with the updated EV fan clutch will improve this condition due to increased air flow across the condenser. The new EV fan clutch has an increased minimum operating fan speed and an improved response time. Additional engine cooling Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1511 Electrical Symbols Part 2 Page 15523 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 5481 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Automatic Control Control Module HVAC: Locations Automatic Control Locations View - HVAC Systems - Automatic Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 5420 Disclaimer Page 15621 Brake Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 7880 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Engine - Correct RTV Sealer Usage Oil Pan: Technical Service Bulletins Engine - Correct RTV Sealer Usage File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-002 Date: January, 2002 INFORMATION Subject: Correct RTV for Usage on 4.2L Engine Models: 2002 Chevrolet and GMC S/T Utility Models (Trailblazer, Envoy) 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Parts are currently available from GMSPO. It is very important that the correct RTV be used on the 4.2L engine. The correct RTV to be used when re-sealing the front cover, rear cover or engine oil pan is shown. Using the wrong RTV may lead to leaks. RTV should be applied using instructions provided in the applicable Service Information. DISCLAIMER Page 10960 1. Apply coolant to the end of the heater inlet hoses. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. 3. Install the coolant bypass valve (6). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nut retaining the coolant bypass valve to the cowel. Tighten Tighten the nut to 10 N.m (89 lb in). 5. Install the vacuum hose to the coolant bypass valve. 6. Install the inlet heater hose to the engine block. 7. Position the inlet heater hose clamp at the engine block using J 38185. 8. Connect the heater inlet hose to the heater core. IMPORTANT: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 9. Install the coolant recovery reservoir. 10. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Intake Air Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Diagrams Intake Air Temperature Sensor Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Page 4204 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 4761 Scan Tool Does Not Power Up - Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Page 1859 Electrical Symbols Part 8 Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information HVAC Systems - Manual Blower Motor Switch: Service and Repair HVAC Systems - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 8910 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 13618 Sun Visor: Removal and Replacement Sunshade Replacement Removal Procedure 1. Remove the windshield garnish molding. 2. Release the front assist handle from the headliner. Refer to Assist Handle Replacement. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). Important: Midway through the rotation cycle, the tool will move further into the access hole. 6. Gently push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade bezel should appear to be recessed. Important: Ensure the bezel is recessed before removing the sunshade from the headliner. 7. In order to remove the sunshade from the roof panel, carefully grab the headliner at the windshield pillar and apply downward pressure while gently rocking the sunshade. 8. Remove the inboard retainer screw. 9. Remove the inboard retainer (1) from the headliner. 10. Reach above the headliner to access the electrical connector (1). 11. Remove the electrical connectors from the headliner substrate. 12. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. Installation Procedure Page 11829 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 692 Locations View Page 12906 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge within the scribe marks on the hinge pillar. 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3-mm (1/8-in) pilot hole at each marked location (1). 4. Drill a 13-mm (1/2-in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 9587 8. Loosen the rear electrical center from the floor of the vehicle. 9. Separate the rear electrical center from its mounting bracket. 10. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 11. Remove the six retaining screws from the console compartment bin and remove the bin. 12. Remove shift lever handle and boot assembly. 13. Remove the screws that retain the console to floor of the vehicle. 14. Set the park brake as firmly as possible, depress Auto Trans Shift Lock Control solenoid plunger and pull the shift lever to the L1 position. 15. Lift the console, disconnect the console wiring and remove the console from the vehicle. 16. Remove the left side closeout/insulator panel (TrailBlazer only). 17. Remove the left side knee bolster (Trail Blazer only). 18. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 19. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (Except TrailBlazer). 20. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 21. Remove the radio retaining screws, pull the radio forward arid disconnect all connectors. 22. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. 23. The radio end of the harness has the foam anti-rattle wrap around it. Feed the radio end of the new harness from under the IP to the area of the radio. 24. Remove the CPA from the radio connector, remove the wires in the cavities listed below from the radio connector and replace them with the wires from the new wiring harness. Important: These wires are twisted pairs and they must be positioned properly in the connector, or audio system performance will be affected. ^ Remove wire in cavity A8 and insert the Tan wire. ^ Remove wire in cavity A9 and insert the Gray wire. ^ Remove wire in cavity A10 and insert the Black wire. ^ Remove wire in cavity A11 and insert the Dark Blue wire. ^ Remove wire in cavity B8 and insert the Brown wire. ^ Remove wire in cavity B9 and insert the Brown/White wire. ^ Remove wire in cavity B10 and insert the Dark Green wire. ^ Remove wire in Cavity B11 and insert the Light Green wire. ^ Reinstall the CPAs to the radio connector. ^ Cut the terminals and the wires of the original harness you removed from the connector. 25. Position the radio in the IP opening, reconnect the connectors and install the retainers. 26. Gently pull the carpet from under the right side of the shifter/console support, route the new wiring harness along and below the right side of the shifter/console support plate, place it under the carpet to the area of the rear audio control and reposition the carpeting. Page 5272 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 1722 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 1343 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Page 13875 Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Page 15599 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 4202 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Instruments - Erratic Speedometer Operation Ground Strap: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 4025 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 6083 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 5205 Locations View Page 2210 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 9029 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. 2.1. Remove all traces of the original adhesive patch. 2.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 2.3. Apply Threadlocker GM P/N 12345493 or Red LOCTITE #272 to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the backing plate bolts. ^ Tighten the backing plate bolts to 95 Nm (71 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 14421 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat cushion bracket mounting nuts (2). 4. Remove the rear seat cushion bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the rear seat cushion bracket to the seat cushion bottom with the four mounting nuts (2). Tighten Tighten the rear seat cushion bracket mounting nuts to 25 N.m (18 lb ft). 2. Install the rear seat bracket trim covers (1). 3. Install the seat in the vehicle. Seat Cushion Panel Replacement - Rear No. 2 REMOVAL PROCEDURE Page 12231 Page 1491 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Locations Locations View Page 5214 Electrical Symbols Part 7 Page 14743 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 4607 Electrical Symbols Part 1 Page 15496 Electrical Symbols Part 8 Page 5373 EVAP Vent Valve 1. Install the EVAP canister vent valve (1) on the bracket (2). 2. Inspect for proper retention of the EVAP vent valve (1) on the bracket (2). 3. Connect the EVAP vent pipe (3) to the EVAP canister vent valve (1). 4. Connect the harness connector (2) to the EVAP canister vent valve. 5. Lower the vehicle Page 5858 Electrical Symbols Part 5 Page 10760 Blower Motor - Auxiliary (Body Type VIN 6) Page 4448 Disclaimer Page 4200 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5776 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9111 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Instrument Panel - Erratic Indicators/Gauges/Pointers Instrument Panel Control Module: All Technical Service Bulletins Instrument Panel - Erratic Indicators/Gauges/Pointers File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-006 Date: May, 2001 TECHNICAL Subject: Erratic Instrument Panel Indicators/Gauges (Needles/Pointers) When Vehicle Ignition is Switched On (Reprogram Instrument Panel Cluster Software) Models: 2002 Chevrolet and GMC S/T Utility Models (New Style) 2002 Oldsmobile Bravada (New Style) Condition Some customers may comment on erratic instrument panel gauge behavior. Any of the six gauges can read much higher than normal or may not return to the minimum scale position with the key off. An example would be the speedometer displaying 30 km/h (20 mph) when the vehicle is not moving. This condition will correct itself after several ignition cycles and, as a result, may not exist when the vehicle reaches the dealership. Correction Open the driver's door and inspect the top right corner of the vehicle certification label for a date. If this date is 06/01 or later, the instrument panel cluster (IPC) software is correct. An PC software change is available to address this issue on vehicles produced prior to 06/01. The software update is available on Techline starting April 14, 2001 on the TIS 2000 version TIS 4.5/2001 data update or later. To update the software, perform normal SPS reprogramming of the IPC using the Tech 2 and the Techline terminal. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 5774 Electrical Symbols Part 8 Page 9537 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 9781 C314 C315 Part 1 Page 1627 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 14254 Seat Lumbar Motors And Position Sensors Assembly - Driver Page 5182 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 14955 Holding the Select button for longer than 3 seconds while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: ^ Range - Can not be reset ^ Avg. Fuel Economy - Can be reset ^ Inst. Fuel Economy - Can not be reset ^ Engine Oil Life - Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0 - 999 MI or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 3 seconds while the Average Fuel Economy is displayed in the DIC will reset both the Trip Distance and Trip Fuel Used to 0.0. Average Fuel Economy is capable of displaying values from 0.0 to 99.9. Display appears as: AVG MPG XX.X (English), AVG L/100 km XX.X XX (Metric), AVG km/l XX.X (Japanese). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 to 99.9. Display appears as INST MPG XX.X (English), INST L/100 km XX.X (Metric), INST km/l XX.X (Japanese). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100%. Display appears as ENGINE OIL LIFE: XXX%. FEATURE PROGRAMMING Refer to Personalization Description and Operation. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Page 12563 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Page 6320 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Locations Locations View Page 11974 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 9415 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 10115 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 10084 8. Place the cylinder line retaining plate (2) over the cylinder line beads at the valve end. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the TORX screw (1) into the cylinder line retaining plate (2) and tighten using an E 8 socket. Tighten the screw to 15 Nm (12 ft. lbs.). 10. Tighten both cylinder line nuts (3) at the cylinder end. Tighten the nuts to 31 Nm (23 ft. lbs.). Page 15459 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 13724 Driver Door Module (DDM) C4 (W/Memory Features) Driver Door Module (DDM) C5 Page 8691 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 13117 10. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. 4. Attach the molding to the outside of the door with double sided tape. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip 9. Install the inner window belt sealing strip. 10. Install the trim panel. Page 14753 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5221 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 9473 C315 Part 2 C316 Page 8509 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement (Trailblazer Ext, Envoy XL) Transfer Case Motor/Encoder Replacement (Trailblazer EXT, Envoy XL) Removal Procedure Important: Before the motor/encoder is removed, ensure that the motor/Encoder is in the neutral position. 1. Raise the vehicle. 2. Remove the transfer case shield, if equipped. 3. Remove the motor/encoder electrical connector. 4. Remove the motor/encoder mounting bolts. 5. Remove the motor/encoder assembly. Installation Procedure Page 7261 Valve Body Spring and Bore Plug Chart (inch) Page 9981 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 8316 1. Install the transfer case front speed sensor. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the fuel tank shield, if equipped. 4. Lower the vehicle. Refer to Vehicle Lifting. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 10250 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Locations Locations View Heater - Insufficient Heat To Driver's Feet Air Duct: All Technical Service Bulletins Heater - Insufficient Heat To Driver's Feet File In Section: 01 - HVAC Bulletin No.: 01-01-38-014 Date: January, 2002 TECHNICAL Subject: Insufficient Heat To Driver's Feet (Install New Floor Air Outlet Duct) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the heater does not warm the driver's feet. Cause The left floor air outlet duct may not direct enough warm air to the area around the driver's feet. Correction Install a new left-hand floor air outlet duct, P/N 15093513 (RPO CJ3 manual HVAC controls) or P/N 15093514 (RPO CJ2 automatic HVAC controls). The new duct has an additional outlet and revised outlet shapes. Refer to the Air Outlet Duct Replacement - Floor LH procedure in the Heating, Ventilation and Air Conditioning section of the Service Manual (SI2000 Document ID # 744975). Parts Information Parts are expected to be available 1-7-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Page 12622 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 14645 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Weatherstrip Replacement - Front Door Opening Removal Procedure 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Page 2881 7. Remove the camshafts. Important: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations. 8. Remove the valve rocker arms. 9. Remove the valve lash adjusters. Installation Procedure Page 12532 Page 1217 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: ^ Ambient Air Temperature Sensor ^ Inside Air Temperature Sensor Assembly ^ Upper Left Air Temperature Sensor ^ Upper Right Air Temperature Sensor ^ Lower Left Air Temperature Sensor ^ Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated as shown in the table. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 5090 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 2509 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 7133 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 5679 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Engine Controls - Hesitation/Idle Fluctuation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Idle Fluctuation Bulletin No.: 03-06-04-018A Date: December 08, 2003 TECHNICAL Subject: Cold Idle Fluctuation at Altitude, Hesitation on Acceleration or 1-2 Upshift Delay (Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VINs - RPO LL8) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 03-06-04-018 (Section 06-Engine). Condition Some customers may comment on one of the following conditions: - Idle fluctuation for a few seconds on the first start up after an overnight soak at higher altitudes. - Hesitation on acceleration, this typically occurs with engine coolant temperatures between 60-80°C (140-175°F). - 1-2 upshift delay at throttle openings of 25% or less and ECT between 7-30°C (45-85°F). Cause The existing PCM calibration may not be optimized for all conditions. Correction Reprogram the PCM with the latest service calibration available from Techline. The Calibrations are electronic calibrations and are NOT available from GMSPO. Calibrations were available from Techline starting February 22, 2003, on the TIS 2000 version 2.5 for 2003 data update or later. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 162 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 13252 Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel Replacement - Lift Gate Trim Panel Replacement - Lift Gate Removal Procedure 1. Open the liftgate window. 2. Remove the push-pin retainer from the trim panel. 3. Close the liftgate window. 4. Open the liftgate. 5. Remove the screw that retains the pullstrap to the liftgate trim panel. 6. Remove the pullstrap from the liftgate trim panel. 7. Use a flat-bladed tool in order to carefully release the trim panel retainers. 8. Remove the trim panel from the liftgate. Installation Procedure 1. Install the trim panel to the liftgate. 2. Ensure that the trim panel retainers are fully seated. 3. Install the pullstrap to the trim panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screw that retains the pullstrap to the trim panel. Page 3611 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Page 9225 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 820 Conversion - English/Metric Page 11719 Page 6250 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13923 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 4278 Electrical Symbols Part 6 Page 371 Disclaimer Page 2226 Power Window Switch: Connector Views Window Switch - LR Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 5687 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 6461 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement (Chevrolet) Removal Procedure 1. Remove the bezel cover. 2. Push in on the two tabs on the side of the control switch. 3. Move the control switch toward the front of the trim plate. 4. Disconnect the electrical connector. 5. Remove the control switch. Installation Procedure 1. Install the electrical connector to the control switch. Important: When installing control switch in the trim bezel, a snap should be felt or heard. Page 5949 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15467 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 9430 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Engine Controls - SES Lamp ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0135 Set Bulletin No.: 03-06-04-034 Date: June 27, 2003 TECHNICAL Subject: Service Engine Soon Light On, DTC P0135 Set (Replace Sensor, Reprogram PCM) Models: 2002 Chevrolet Trailblazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon (SES) light coming on. Upon investigation, the technician will find diagnostic trouble code (DTC) P0135 set, regarding oxygen sensor performance. Cause Condition may be due to failure of the oxygen sensor. Correction Follow the SI diagnostics to confirm that the oxygen sensor has failed. Replace the oxygen sensor. After replacing the sensor, verify that the vehicle has been programmed with the latest service calibration. If the vehicle does not have the latest service calibration listed in TIS2000 version 2.5 or higher released February 22, 2003, then reprogram the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 2. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 4023 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Locations Locations View Page 3850 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 15470 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6018 Electrical Symbols Part 2 Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 3016 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 10397 Pry the yoke away from the control arm to install the J 36607. 6. Remove the J 36607 and the shock module yoke to lower control arm retaining nut. 7. Remove the shock module from the shock tower and lower control arm. Installation Procedure 1. Install the shock module to the shock tower and lower control arm. 2. Install the shock module yoke to the lower control arm. 3. Lower the vehicle. 4. Install the shock module upper retaining nuts. Tighten the shock module upper retaining nuts to 45 Nm (33 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Raise the vehicle. Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Clutch: All Technical Service Bulletins Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Page 33 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 13572 34. Pass the communication interface module electrical connectors through the small hole in the carpet. 35. Install the headliner harness retaining clips to the rocker panel and the floor panel. 36. If equipped with OnStar(R) perform the following procedure: 36.1. Install the navigation antenna cable to the right 'C' pillar. 36.2. Install the navigation antenna cable to the floor studs. 37. Install the body electrical block. 38. Install the rear carpet Ensure that the carpet hooks over the left wheelhouse panel stud. Page 4717 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 2439 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the nut from compressor hose connection in driver wheel opening. 12. Remove the O-ring seals. 13. Cap or plug all of the open connections. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor discharge hose nut. Tighten Tighten the hose nut to 28 N.m (21 lb ft). 4. Install the compressor hose to the connector in driver wheel opening. 5. Install the nut. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 11232 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the inflatable restraint steering wheel module. Refer to Air Bag(s) Arming and Disarming. 2. Tilt the steering column to the CENTER position. 3. Remove the steering wheel from the column. 4. Remove the upper and lower trim covers. 5. If necessary, check the steering column for accident damage. Refer to Steering Column Accident Damage Inspection. IMPORTANT: If the steering wheel has PAD control, the inflatable restraint steering wheel module coil and wire harness assembly must come off as one piece. If the steering wheel does not have PAD control, the inflatable restraint steering wheel module coil will come off by itself. 6. Remove the wire harness strap. 7. If the steering wheel has PAD control remove the wire harness assembly. Refer to Steering Column Wire Harness Assembly Replacement. 8. Remove the retaining ring (1) using snap ring pliers. 9. Remove the inflatable restraint steering wheel module coil (2). 10. If necessary, remove the wave washer (3). INSTALLATION PROCEDURE Page 805 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 5880 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 12184 Speaker: Service and Repair Speaker Replacement - Rear Door REMOVAL PROCEDURE 1. Remove the rear door trim panel. 2. Remove the water deflector. 3. Disconnect the speaker electrical connector. 4. Remove the 3 speaker retaining bolts. 5. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Install the speaker to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 speaker retaining bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the speaker electrical connector. 4. Install the water deflector. 5. Install the rear door trim panel. Electrical - No Start/Multiple Systems Inoperative Driver/Vehicle Information Display: Customer Interest Electrical - No Start/Multiple Systems Inoperative File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-03-001 Date: January, 2002 TECHNICAL Subject: No Start, Turn/Hazard, Interior Lamps, DIC, Radio, Theft Alarm, Wipers, Cruise, Shift Interlock, Horn and/or Key In Signal Inoperative (Repair/Insulate Steering Column Wiring Harness) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Built Prior to VIN Breakpoint 22238123 Condition Some customers may comment that the vehicle will not start and/or any of the following functions may be inoperative: ^ The turn/hazard lamps ^ Interior lighting ^ The Driver Information Center (DIC) ^ The radio/entertainment ^ The wiper/washers ^ The theft alarm ^ The cruise control ^ The key-in signal ^ The shift interlock ^ The horn Cause A pinched, chafed or cut wire in the steering column harness against the knee bolster bracket may cause this condition. Correction Follow the service procedure below to repair and insulate the steering column wiring harness. 1. Remove the two screws that retain the left insulator panel to the IP at the base of the steering column. 2. Position the insulator panel down and out of the way in order to allow removal of the knee bolster. 3. Remove the four knee bolster trim panel retaining screws. 4. Release the clips that retain the trim panel to the IP. 5. Remove the trim panel from the IP. 6. Locate the wiring harness at the LH bottom corner of the knee bolster support bracket and inspect for a pinched, chafed or cut wire at that point in the harness. 7. Repair any pinched, chafed or cut wires in the harness. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual (SI2000 Page 11737 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). A/T, Exhaust - Rattling Noise From Under the Vehicle Fluid Line/Hose: Customer Interest A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4634 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 13264 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Refer to Wiper Motor Replacement - Rear. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 10504 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 2628 Fuse Block - Underhood C3 Page 13668 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Ride/Trim Height Inspection Procedure Alignment: Service and Repair Ride/Trim Height Inspection Procedure TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following prior to measuring trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement - Front The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the high and the low measurements. Cross vehicle Z heights should be within 24 mm (0.9 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage. D Height Measurement - Rear The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. Page 3759 Installation Procedure 1. If replacing the whole muffler pipe assembly, carefully install the muffler into place on the vehicle and secure the exhaust hangars to the insulators. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the muffler to the catalytic converter pipe and secure the pipe with the nuts. ^ Tighten the muffler to converter pipe nuts to 45 Nm (33 ft. lbs.). 3. If replacing exhaust aft of the muffler: ^ Connect exhaust to insulators as required. ^ Install exhaust pipe to muffler. ^ Tighten the exhaust pipe clamp nuts to 50 Nm (37 ft. lbs.). ^ Remove the exhaust support. 4. Inspect the exhaust system for leaks and underbody contact. 5. Lower the vehicle. Page 4614 Electrical Symbols Part 8 Page 6947 8. Remove the cooler lines (3,4) from the radiator. 9. Separate the front and rear cooler lines at the quick connect fitting (2). 10. Remove the cooler lines from the retainer (1) located on the radiator shroud. 11. Remove the front sections of the cooler lines from the vehicle. 12. Remove the rear sections of the cooler lines from the retainer (1) located on the right side of the engine. 13. Remove the clip (2) that holds the cooler lines together. 14. Support the transmission with a transmission jack. 15. Remove the transmission support. 16. Remove the front exhaust pipe assembly. 17. Carefully lower the transmission to gain access to the cooler line fittings. 18. Place a drain pan under the vehicle. 19. Disconnect the oil cooler lines (4) from the transmission. 20. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). 21. Remove the oil cooler lines from the vehicle. Installation Procedure Specifications Fluid Pan: Specifications Oil Pan to Transmission Case Bolt ........................................................................................................................................................ 11 Nm (97 inch lbs.) (Tighten bolts alternately and evenly) Page 803 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4998 Powertrain Control Module (PCM) C2 Part 2 Page 4641 Crankshaft Position (CKP) Sensor Page 14175 3. Install the front seat head restraint. Head Restraint Replacement - Rear Seat REMOVAL PROCEDURE 1. Raise the head restraint to the full up position. 2. Adjust the seat cushion just below the top of the seat back in order to gain access to the retaining clip on each head restraint post. 3. Remove the retaining clip from each head restraint post. 4. Remove the head restraint from the seat back. INSTALLATION PROCEDURE 1. Install the retaining clips to the head restraint retractor. Page 1771 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Diagram Information and Instructions Volt Meter Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 8500 Transfer Case Actuator: Specifications NVG126-NP4 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) NVG 226-NP8 Transfer Case Motor/Encoder Bolts ......................................................................................................................................................... 16 Nm (12 lb ft) Page 1854 Electrical Symbols Part 3 Page 12508 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 11128 Locations View - HVAC Systems - Automatic Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9162 For vehicles repaired under warranty, use the table. Disclaimer AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: Customer Interest Rearview Mirrors (Outside) - Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 2508 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 1575 Disclaimer Page 4030 Conversion - English/Metric Page 765 Various symbols are used in order to describe different service operations. Page 5342 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 8206 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 5092 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Page 4062 Electrical Symbols Part 3 Page 7765 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11323 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Page 12078 Garage Door Opener Inoperative - Steps 1-10 Page 235 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 15619 Brake Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Page 9917 Disclaimer Page 8805 Page 15709 Electrical Symbols Part 4 Page 4612 Electrical Symbols Part 6 Page 13636 8. Partially remove the trim panel in order to remove the inflator switch from the inflator bezel. 9. Remove the auxiliary air outlet washer and retaining nut. 10. Feed the auxiliary air outlet through the inflator bezel. 11. Remove the inflator bezel from the trim panel. 12. Disconnect the the 12-volt power supply electrical connector. 13. Remove the 12-volt power supply. 14. Remove the trim panel from the vehicle. INSTALLATION PROCEDURE 1. Position the trim panel to the vehicle. 2. Install the 12-volt power supply. 3. Connect the 12-volt power supply electrical connector. 4. Install the inflator bezel to the trim panel. 5. reed the auxiliary air outlet through the hole in the inflator bezel. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the auxiliary air outlet washer and retaining nut. Tighten Tighten the nut to 2 N.m (18 lb in). 7. Install the inflator switch to the inflator bezel. Page 250 Circuit/System Testing Component Testing Service and Repair Evaporator Drain Tube: Service and Repair EVAPORATOR DRAIN HOSE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the HVAC module pass through seal (3) from the HVAC module-auxiliary (1). 3. Remove the evaporator drain hose-auxiliary (2) from the HVAC module-auxiliary (1). INSTALLATION PROCEDURE 1. Install the evaporator drain hose-auxiliary (2) to the HVAC module-auxiliary (1). 2. Install the HVAC module pass through seal (3) to the HVAC module-auxiliary (1). 3. Install the HVAC module-auxiliary. Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 12430 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 13050 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Specifications Fuel Level Specifications Page 10023 10. Remove the power steering hose assembly bracket retaining bolt at the wheel well. 11. Disconnect the power steering hose assembly bracket from the wheel well. 12. Remove the power steering hose assembly to frame brackets retaining bolts. 13. Remove the power steering hose assembly to front crossmember bracket mounting bolt. 14. Remove the power steering pressure hose (1) and power steering cooler hose (2) from the power steering pump. 15. Remove the power steering hose assembly from the vehicle. Installation Procedure 1. Install the power steering hose assembly to the vehicle. 2. Install the power steering cooler hose (2) to the power steering pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose (1) to the power steering pump. Tighten the power steering pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). Page 481 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 9346 Auxiliary Power Outlet: Locations Locations View Recall 01V126000: Front Lower Control Arm Bracket Defect Control Arm: All Technical Service Bulletins Recall 01V126000: Front Lower Control Arm Bracket Defect Vehicle Description: Sport utility vehicles. Under certain circumstances the front lower control arm brackets may fracture. This fracture could result in separation of the front lower control arm from the frame. A separation could result in loss of vehicle control, resulting in a crash. Dealers will replace the left and right front lower control arm brackets. Owner notification began by telephone on April 4, 2001. The followup letter to consumers was mailed May 3, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020, Oldsmobile at 1-800-442-6537, or GMC at 1-800-462-8782. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 14369 9. Release the hook and loop fasteners (2, 3) securing the cover to the pad. 10. Remove the three hog rings (1) securing the cover to the pad. 11. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. 12. Remove the seat back cover and pad. The pad may be glued to the frame in places from the initial set assembly process. INSTALLATION PROCEDURE Page 8192 4. Remove the Actuator Asm, Trfer Case Four WhI Drv (Motor) mounting bolts. 5. Remove the motor from the transfer case and set aside. 6. Position an oil drain container into position under the transfer case drain plug. Remove the drain plug and allow the transfer case to drain. 7. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Release the tabs to allow removal and discard the gasket. Important: Gently lift and tilt the sensor toward the wiring connector wiring to disconnect it. You will notice the two wires to the motor. The red and black wires go to an internal connector within the motor housing. The black plastic connector for these wires does not have a locking tab and is easily disturbed. 8. Lift/pry the sensor from the motor shaft. Disconnect the sensor from the wiring harness. Important: Look at the motor where you just removed the sensor. You will notice the Hex" in the casting where the new sensor will seat when properly installed. 9. Connect the wiring harness to the sensor. 10. Gently insert a suitable tool along side the red and black wires and press down on the black plastic connector to ensure the connector is in the proper position. 11. Properly align the key way of the sensor on the shaft and install the sensor. Ensure that the hex on the sensor fits in the hex of the casting. Specifications Camshaft: Specifications Camshaft Cap Bolt 106 inch lbs. Camshaft Journal Diameter-All Intake and Exhaust #2 - #7 1.0612-1.0622 inch Journal Diameter - Exhaust #1 1.1794-1.1804 inch Camshaft Bore Diameter - All Intake and Exhaust #2 - #7 1.0638-1.0646 inch Camshaft Bore Diameter-Exhaust #1 1.1820-1.1828 inch Journal Clearance 0.0015-0.0033 inch Camshaft Endplay- Intake 0.0020-0.0079 inch Camshaft Endplay - Exhaust 0.0017-0.0084 inch Page 10934 3. Install the HVAC module-auxiliary case sump (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the HVAC module-auxiliary case sump. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the blower motor control processor-auxiliary. 6. Install the backing plate (1) to the evaporator core-auxiliary. 7. Install the evaporator block-auxiliary. 8. Install the inverted torx studs to the evaporator block-auxiliary. Tighten Tighten the torx studs to 2 N.m (18 lb in). 9. Install the heater core-auxiliary. 10. Leak test the fittings of the component using the J 39400-A. Page 4866 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13275 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Window Strut Replacement - Lift Gate Window Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate window. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the liftgate window struts using a small flat-bladed tool. 3. Remove the upper end of the liftgate window struts from the ball joint. 4. Remove the lower end of the liftgate window struts from the ball joint. 5. Remove the liftgate window struts from the liftgate window. Installation Procedure Notice: Apply pressure only at the end of the hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Position the liftgate window struts to the liftgate window. 2. Install the upper end of the liftgate window struts to the ball joint. Press in to place until fully seated. 3. Install the lower end of the liftgate window struts to the ball joint. Press in to place until fully seated. 4. Remove the support device from the liftgate window. 5. Close the liftgate window. Fog Lamp Relay Replacement (RPO T96) Fog/Driving Lamp Relay: Service and Repair Fog Lamp Relay Replacement (RPO T96) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Open and support the hood. 2. Remove the protective covers from the underhood junction block. 3. Use the J 43244 in order to remove the fog lamp relay (1) from the underhood junction block. INSTALLATION PROCEDURE 1. Use the J 43244 in order to install the fog lamp relay (1) to the underhood junction block. 2. Install the protective covers to the underhood junction block. 3. Close the hood. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Page 3036 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drivebelt. 2. Inspect the drivebelt. Change the drivebelt as necessary. 3. Using a wrench loosen and remove the drivebelt tensioner bolt. 4. Remove the drivebelt tensioner. Installation Procedure 1. Install the drive belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drive belt tensioner bolt. ^ Tighten the drive belt tensioner bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt Drive Belt Replacement. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 12572 Parts Information Page 10051 Power Steering Pump: Testing and Inspection Please see STEERING/TESTING and INSPECTION for information on this component. Page 7729 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Front Door Window Belt Outer Front Door Window Glass Weatherstrip: Service and Repair Front Door Window Belt Outer REMOVAL PROCEDURE 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. INSTALLATION PROCEDURE 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten Tighten the screw to 1.2 N.m (10 lb in). Page 2339 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-965 Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 19 1. Attach the radio antenna module to the headliner retaining strips. 2. Connect the coax cable to the radio antenna module. 3. Connect the electrical connector to the radio antenna module. 4. Connect the radio antenna module electrical connector to the stationary glass. 5. Install the rear headliner to roof retainers. 6. Install the left coat hook. Page 3865 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 5370 Evaporative Emission (EVAP) Canister Vent Solenoid Page 11233 1. If necessary, install the wave washer (1). 2. Align the block tooth on the steering. shaft assembly (1) to the 12 o'clock position. IMPORTANT: A new inflatable restraint steering wheel module coil is pre-centered. Do not remove the centering tab from the new inflatable restraint steering wheel module coil until installation is complete. Page 4052 Intake Air Temperature (IAT) Sensor Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: Customer Interest Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 11605 Locations View Specifications Engine Block Heater: Specifications Heater Inlet Fitting 33 ft. lbs. Heater Outlet Fitting 33 ft. lbs. Coolant Heater 37 inch lbs. Page 2721 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 7066 For vehicles repaired under warranty, use the table. Disclaimer Page 13637 8. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 9. Align the locating tabs on the trim panel to the holes in the body. 10. Seat the clips that retain the trim panel to the body. 11. Install the seat belt lower anchor. Tighten Tighten the anchor bolt to 70.0 N.m (52 lb ft). 12. Install the right rear door sill panel. 13. Install the liftgate sill plate. 14. Install the trim panel-rear quarter upper. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the right body side window rear garnish molding. 4. Remove the right body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the right rear door sill panel. 7. Remove the lower seat belt anchor bolt. Page 2736 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 8485 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 5672 Electrical Symbols Part 2 Page 12741 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, remove the BCM (1) from the rear electrical center. Page 5811 Electrical Symbols Part 4 Page 5464 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Fuse Block - Rear Locations View Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 10787 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Recline the driver seat rearward to access the left center trim pillar. 1. Remove the upper portion of the left center trim pillar. 2. Disconnect the electrical connector. 3. Remove the retaining clips from the B pillar. 4. Remove the inside air temperature sensor assembly (1) from the B pillar. INSTALLATION PROCEDURE 1. Connect the electrical connector to the inside air temperature sensor assembly (1). 2. Install the inside air temperature sensor assembly (1) to the B pillar. 3. Install the retaining clips to the B pillar. 4. Install the upper portion of the left center trim pillar. Page 15675 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 9956 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 2480 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 14795 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Steering - Hissing Noise From Steering Column Steering Shaft: Customer Interest Steering - Hissing Noise From Steering Column Bulletin No.: 05-02-35-006A Date: October 04, 2005 TECHNICAL Subject: Hiss/Rush Noise From Steering (STRG) Column Area (Replace Lower Intermediate Shaft) Models: 2004-2005 Buick Rainier Models 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Models Supercede: This bulletin is being revised to correct the Labor Operation Number. The original bulletin incorrectly states to use Labor Operation E7770. The correct Labor Operation is E7700. Please discard Corporate Bulletin Number 05-02-35-006 (Section 02 - Steering). Condition Some customers may comment on a low volume hiss and/or rush noise heard from the steering column area. The noise may change when the steering wheel is rotated in either direction. The noise may be noticeable with the engine ON, vehicle in PARK, HVAC and Radio OFF. Cause The lower steering column intermediate shaft may be internally grounding out, creating a noise path. Diagnosis and Correction To determine if the lower intermediate shaft is allowing noise to travel from the power steering hydraulic system into the vehicle passenger compartment, follow the steps below. 1. Confirm the customer's concern. Note: Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: All Technical Service Bulletins Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 8742 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 4538 Body Control Module: Description and Operation The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the Driver Door Module (DDM), Passenger Door Module (PDM) and the Liftgate Module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 4976 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 4730 Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM mounting studs (1) to the intake manifold, if necessary. Tighten Tighten the studs to 6 N.m (53 lb in). Install the PCM (2) to the intake manifold. 2. Install the PCM mounting nuts and bolts (3). Tighten Tighten the nuts and bolts to 10 N.m (89 lb in). 3. Install the PCM harness connectors (3) to the PCM (2). 4. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 5. If a new PCM is being installed, the PCM must be programmed. See: Testing and Inspection/Programming and Relearning Page 8490 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 4243 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 9219 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 13031 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 13694 Electrical Symbols Part 8 Page 12309 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 8719 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 3846 Electrical Symbols Part 5 Page 7180 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 470 Memory Seat Module - Passenger C3 Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Body/Frame - Roof Rack Wind Noise Roof Rack Frame: All Technical Service Bulletins Body/Frame - Roof Rack Wind Noise File in Section: 08 - Body and Accessories Bulletin No.: 02-08-67-005 Date: May, 2002 INFORMATION Subject: Proper Position and Installation of Roof Rack Cross Rails to Reduce Wind Noise Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBrazer, TrailBlazer EXT, Envoy, Envoy XL) 2002 Oldsmobile Bravada Some of the above vehicles may exhibit wind noise related to the roof rack. In an effort to reduce wind noise, Engineering has identified a specific position and installation for the roof rack cross rails. ^ Beginning on September 6, 2001 the TrailBlazer, Envoy, and Bravada were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the TrailBlazer EXT and Envoy XL were built with the roof rack cross rails installed in the reverse direction (arrows towards rear of vehicle). ^ Early calendar year 2002 the directional arrows were removed from the cross rails on all models to eliminate any confusion as to which direction is correct. It has been found that some dealers are changing the direction of the cross rails thinking they were installed incorrectly. To obtain the optimum position and installation of the roof rack cross rails that produce the least wind noise, use the following procedure: 1. If the cross rails have directional arrows, they should be installed in the reverse direction (arrows toward rear of vehicle). Remove the cross rails and rotate as necessary. 2. If the directional arrows are not present, installation can be verified by checking the location of the cross rail eyelets. When the location of the cross rail eyelets. When installed in the reverse direction, the cross rail eyelets will face the rear of the vehicle. Remove the cross rails and rotate as necessary. 3. Once the specified direction has been established, adjust the position of the cross rails, so that one cross rail is positioned at the rear most end of the vehicle. The other cross rail should then be positioned at approximately midpoint of the rear door glass. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9136 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Page 3474 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 14314 1. Install the wiring harness and connector clips, if you replaced the frame. 2. Install the seat memory module, if equipped. 3. Install the seat cushion cover and pad to the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 5. Install the seat harness to the seat pan. 6. Install the SIR harness (2) to the seat clips (1, 4). 7. Connect the gray lumbar electrical connector (5), if equipped. 8. Connect the black electrical connector (3) to the seat belt buckle. 9. Connect the black electrical connector (6) to the seat back harness. 10. Install the 3 seat switch bezel mounting screws. Page 4005 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 10991 Hose/Line HVAC: Service and Repair A/C Pipe Replacement/Repair - Auxiliary TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: ^ Rub-through ^ Collision damage ^ Leakage in the system Minimum Tube Length Required Table IMPORTANT: When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. IMPORTANT: The length of the replacement line must be the same as the section being replaced. 7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from the J 41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. IMPORTANT: Hold the J 41425-1 tool body with a 3/8" breaker bar. 15. Tighten the forcing screw of the J 41425-1 tool. When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to complete the line splice. 18. Verify that the LOK fittings are correctly installed. Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 7608 K. Transfer data file to the scan tool. L. Position the left side second row seat in order to access the rear fuse block. M. Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse. N. Reconnect the scan tool to the vehicle. 0. Turn ON the ignition, with the engine OFF. P. Select the Service Programming feature on the scan tool. Q. Press the Program button on the scan tool. R. Install fuse and reposition the seat. 2. Perform system check by shifting transfer case to all modes of operation. 3. Install the GM Recall Identification Label. Page 13811 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 1273 Low Pressure Sensor / Switch: Description and Operation HVAC Systems - Automatic A/C LOW PRESSURE SWITCH A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 2196 Electrical Symbols Part 5 Page 13077 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 816 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 15788 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 2110 Disclaimer Page 12070 Equivalents - Decimal And Metric Part 1 Page 9628 Auxiliary Power Outlet - Front Page 8975 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. ^ Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. Page 8296 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 5098 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Page 14008 11. Connect the mirror heater and electrochromic mirror glass connectors to the mirror. Use a new mirror glass if the original one was damaged or broken during the removal procedure. Clip the electrochromic harness connector to the back of the mirror glass and route the mirror wires as shown in the illustration above. 12. Install the mirror glass into the mirror housing by pushing the mirror glass onto the mirror actuator, ensuring that all the retaining tabs are fully seated. 13. Repeat this replacement procedure if the mirror actuator is being replaced on the right side of the vehicle. 14. Verify proper operation of both mirror assemblies. Parts Information Parts are expected to be available 4-2-2002 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt 37 ft. lbs. Page 3131 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 807 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 15290 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 6369 The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is not shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Service Procedure IMPORTANT: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. Clean Neutral Test Caution: Please use the parking brake when the vehicle is parked or left unattended. 1. Position the vehicle on a level surface, engine on, and apply the service brake. IMPORTANT: ENSURE FRONT AND REAR OF VEHICLE ARE CLEAR OF BUILDINGS, OTHER VEHICLES AND PERSONNEL. 2. Place the transmission in neutral and shift the transfer case to neutral (Rotate and hold the transfer case shift selector switch past 4Lo for ten seconds. An "N" indicator light on the switch will indicate the shift. The vehicle speed must be below 3 mph, (5 kph)). ^ Shift the transmission to Reverse, then to Neutral and then to Drive; release the service brake, but keep the transfer case in neutral. ^ While in Drive VERY LIGHTLY press the throttle, then release the throttle. ^ Shift the transmission to neutral and repeat light throttle, then release the throttle. ^ Shift the transmission to reverse and repeat light throttle. ^ If the vehicle does not move under power (depending on the testing surface, the vehicle could still roll because the transfer case is in neutral) and makes no noise (e.g. ratcheting noise, gear face contact noise) in the transfer case beyond noises that would be expected from the transmission or transfer case as detected at the driver's location (a clean neutral), go to Active Transfer Case Control Module Reprogramming and update with calibration # 12575794. ^ If the vehicle does move under power or makes a noise (e.g. ratcheting noise, gear face contact noise), replace the transfer case. The transfer Fuse Block - Rear Fuse Block: Locations Fuse Block - Rear Fuse Block Rear Locations View Located under the left rear seat. Page 13328 Disclaimer Page 10843 Locations View - HVAC Systems - Manual Page 14760 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 8937 1. Install the backing plate to the axle housing flange. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate nuts. ^ Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 3. Install the rear drive axle. 4. Install the park brake shoe. Page 12839 Rear Bumper Reinforcement: Service and Repair Impact Bar Replacement - Rear Bumper Removal Procedure 1. Remove the spare tire carrier. 2. Remove the rear fascia. 3. Disconnect the trailer/towing receptacle electrical connector. 4. Rotate the trailer/towing receptacle assembly counter-clockwise and remove from the vehicle. 5. Remove the 4 rearward bolts that retain the impact bar assembly to the frame rails. 6. While an assistant holds the impact bar (1) assembly in place, remove the remaining 2 retaining bolts. 7. Remove the impact bar (1) assembly from the vehicle with an assistant. Installation Procedure 1. Position the impact bar (1) assembly to the vehicle with an assistant. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the rear impact bar to the frame. Tighten the rear impact bar bolts to 364 N.m (268 lb ft). Page 15753 Glove Box Lamp: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the instrument panel (IP) compartment and release the stop latch in order to lower IP compartment to the full down position. 2. Remove the 5 screws that retain the IP compartment jamb trim panel to the Instrument panel (IP). 3. Disconnect the electrical connector to the socket assembly. 4. Remove the trim panel from the IP. 5. Release the socket assembly retaining tabs. 6. Remove the socket assembly from the trim panel. 7. Remove the bulb from the socket. INSTALLATION PROCEDURE Page 14287 Seat Adjuster Switch - Front Passenger (W/Memory Seat) Page 3899 Electrical Symbols Part 4 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: - Block the drive wheels. - Apply the vehicles parking brake. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn OFF the A/C. - Place the vehicle's transmission in Park (A/T) or Neutral (M/T). - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the crankshaft position system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 14281 Lumbar Adjuster Switch - Passenger (W/O Memory Seat) Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the fuel tank shield fasteners and remove the fuel tank shield, if applicable. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 3. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. 4. Turn ON the ignition. Page 208 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 2451 4. Install the power steering hose assembly to front crossmember bracket mounting bolt. Tighten the power steering hose assembly to front crossmember bracket mounting bolt to 10 Nm (7 ft. lbs.). 5. Install the power steering hose assembly to frame brackets retaining bolts. Tighten the power steering hose assembly to frame brackets retaining bolts to 10 Nm (7 ft. lbs.). 6. Connect the power steering hose assembly bracket to the wheel well. 7. Install the power steering hose assembly bracket retaining bolt at the wheel well. Tighten the power steering hose assembly bracket retaining bolt at the wheel well to 10 Nm (7 ft. lbs.). 8. Install the fuse block. 9. Install the battery tray. 10. Connect the fuse block harnesses to the wiring loops. 11. Raise the vehicle. Refer to Vehicle Lifting. 12. Install the power steering return hose and the power steering cooler hose to the power steering cooler. 13. Remove the power steering gear oil seals from the power steering gear using J44586. Notice: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 14. Clean the power steering gear inlet and outlet ports of any debris. 15. Install the power steering gear oil seals to the power steering gear using J44586. Page 2219 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 4590 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 15359 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 15565 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Page 15897 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 4506 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 10965 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 5927 Electrical Symbols Part 1 Page 5756 Conversion - English/Metric Page 2665 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady malfunction indicator lamp (MIL) with the ignition ON and the engine OFF. MIL OPERATION The malfunction indicator lamp (MIL) is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible ^ The MIL illuminates during a bulb test and a system test. ^ A diagnostic trouble code (DTC) will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with the ignition ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Page 16031 Door Switch: Diagrams RR Miniwedge (Door Jamb Switch) - RR Miniwedge (Door Jamb Switch) - RR Page 14615 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 15452 Electrical Symbols Part 5 Page 6939 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 1646 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 7480 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease lubricate the shaft with grease (GM P/N 12377985 or equivalent). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the yoke retainers and the bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Page 3452 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 3978 Camshaft Position Sensor: Connector Views Camshaft Position (CMP) Sensor Camshaft Actuator Solenoid Assembly Page 1278 Ambient Light/Sunload Sensor Assembly Page 13633 Tighten the anchor bolt to 70. N.m (52 lb ft). 6. Install the left rear door sill panel. 7. Install the liftgate sill plate. 8. Install the left body side upper trim panel. Trailblazer EXT, and Envoy XL REMOVAL PROCEDURE 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the left body side window rear garnish molding. 4. Remove the left body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the left rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Remove the auxiliary power outlet from the trim panel. Page 2202 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 10383 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Coil Spring Replacement Removal Procedure Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Install the rear axle support. 3. Remove the shock absorber lower mounting bolts. Notice: Do not lower the rear axle so that the upper control arms contact the frame. Damage to the upper control arms will result. 4. Lower the rear axle. 5. Remove the rear coil springs. Installation Procedure Page 4993 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 1949 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 7677 Page 1755 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 5328 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11841 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 12010 2. Partially install the front bracket retaining bolts. 3. Carefully pull down on the rearward edge of the headliner in order to expose the rear bolt installation area. 4. Partially install the rear bracket retaining bolt. NOTE: Refer to Fastener Notice in ice Precautions. 5. Fully seat the retaining bolts. Tighten Tighten the bolts to 10 N.m (88 lb in). 6. Install the two rear overhead console carrier screws (1). Tighten Tighten the screws to 1.2 N.m (10 lb in). 7. Install the video display assembly. 9. Close the video display screen. 10. Install the bolt cover bezel. A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 11682 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 11213 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the connector position assurance (CPA) to the RF side impact module yellow 2-way connector (2) located under the passenger seat. 4. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 5. Install the CPA to the LF side impact module yellow 2-way connector (2) located under the driver seat. 6. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 7. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. Page 5213 Electrical Symbols Part 6 Hinge Replacement - Rear Door - Body Side Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Body Side Hinge Replacement - Rear Door - Body Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the 4 weld locations. Page 1388 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 1331 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3601 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3186 Page 4019 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 15 5. Install the upper and lower trim covers. 6. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in Restraint Systems. 7. Program the Theft Deterrent Control Module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Page 13057 Rear Door Latch: Service and Repair Latch Replacement - Rear Door Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the inside door handle lock rods from the latch. 5. Disconnect the outside handle lock rod from the outside handle. 6. Remove the 3 fasteners that retain the latch to the door. 7. Disconnect the electrical connectors from the latch. 8. Remove the latch from the door. 9. Remove the actuator from the latch. Installation Procedure 1. Install the actuator to the latch. 2. Position the latch to the door. 3. Connect the electrical connectors to the latch. Page 5318 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14231 For vehicles repaired under warranty, use the table. Disclaimer Page 14280 Lumbar Adjuster Switch - Passenger(W/Memory Seat) Page 4027 Equivalents - Decimal And Metric Part 1 Page 4302 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 3457 Coolant: Fluid Type Specifications Type Goodwrench(R) or Havoline(R) Silicate-Free DEX-COOL(R) 50/50 mixture of clean, drinkable water (preferable distilled). Page 8288 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 5501 1. Lubricate the new injector O-ring seals (2, 4) with clean engine oil. 2. Install the new injector O-ring seals on the injector. 3. Install a new retainer clip (1) on the injector. 4. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail assembly. Page 11222 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) Part 1 Page 6034 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 14370 1. Position the seat back cover and pad on the seat back frame. 2. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 3. Install the three hog rings (1) securing the cover to the pad. 4. Pull the cover down over the pad ensuring that the hook and loop fasteners (2, 3) are pressed together. 5. Pull the seat cover back through the opening between the seat cushion and the seat back. Page 14762 Equivalents - Decimal And Metric Part 1 Page 14426 1. Install the trim panel to the power seat by performing the following steps: 1. Align the trim panel to the seat assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws retaining the trim panel to the seat assembly. Tighten the trim panel screws to 3 N.m (26 lb in). 3. Install the 3 seat switch bezel mounting screws. Tighten the seat switch bezel mounting screws to 3 N.m (26 lb ft). 2. Install the trim panel to the manual seat by performing the following steps: 1. Install the screws in the trim panel. 2. Install the lumbar support knob. 3. Install the seat back recliner handle. Seat Cushion Cover and Pad Replacement - Front Seat Cushion Cover and Pad Replacement - Front Removal Procedure 1. Remove the 3 seat switch bezel screws. 2. Remove the 4 nuts that retain the seat pan to the seat adjuster assembly. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. Page 4599 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 13049 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 2534 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Page 9988 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3812 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. 6. Install the rear electrical center cover. 7. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 7859 5. Remove the motor/encoder assembly. Important: When replacing the encoder rotary position sensor follow these additional steps. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder gasket. 6. Position the motor on a work bench. 7. Release the 4 tabs that retain the motor/encoder gasket and remove the gasket (1). 8. Remove the snap ring and washer retaining the motor/encoder rotary position sensor. Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed. 9. Lift the motor/encoder rotary position sensor (2) from the motor shaft. 10. Disconnect the rotary position sensor (2) from the wiring harness. Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed. Installation Procedure Important: Provided the rotary position sensor was removed, follow steps to install the sensor, otherwise proceed to installing the motor/encoder to the transfer case. 1. Connect the wiring harness to the rotary position sensor. 2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed. Specifications Air Line: Specifications Air Supply Lines to Air Spring Compressor 20 inch lbs. AWD/4WD System - Delayed Front Wheel Engagement Control Module: All Technical Service Bulletins AWD/4WD System - Delayed Front Wheel Engagement Bulletin No.: 04-04-21-001 Date: May 14, 2004 TECHNICAL Subject: Delayed Engagement of Front Wheels During a Slip Condition (Reprogram Transfer Case Control Module (TCCM)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with New Venture Gear (NVG) 126 (RPO NP4) or NVG 226 (RPO NP8) Transfer Case Condition Some customers may comment on a hesitation or delayed engagement of the front wheels during a slip condition. This condition may manifest itself in the normal AWD mode for the Bravada and Rainier models, and in the Auto 4WD mode for the TrailBlazer and Envoy models. Correction Reprogram the Transfer Case Control Module (TCCM) using normal SPS procedures using TIS software version 11.5 released November 10th, 2003 or newer. Refer to Transfer Case Control Module Reprogramming for additional information. 2002 vehicles will require the replacement of the transfer case control module prior to reprogramming. Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Page 9057 6. Remove the park brake cable from the park brake lever. 7. Slide the park brake shoe (2) down until it is disengaged from the hold down spring (3). 8. Lift the shoe (2) away from the backing plate and slide the shoe up, off of the actuation mechanism (1). 9. Remove the shoe (2) over the axle flange and from the vehicle. 10. Clean the debris and the dust from the park brake components using a clean towel. 11. Turn the adjustment screw to the fully home position in the notched adjustment nut, then back it off 1/4 turn. 12. Align the slots in both the adjusting screw and tappet to be parallel with the backing plate face. 13. Using denatured alcohol, clean the rear backing plate of dirt and foreign materials. 14. Using non-lubricated, filtered air, dry the backing plate. Installation Procedure 1. Install a new park brake shoe (2) over the axle flange. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 702 INSTALLATION PROCEDURE IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. Page 1721 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 8921 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 11274 12. Twist together 2 connector wire leads-the high circuits from both stages of the steering wheel module-to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits. 13. Inspect that the 3 wire connection is secure. 14. Bend flat the twisted connection. 15. Secure and insulate the 3 wire connection to the deployment harness using electrical tape. Page 1355 Turn Signal/Multifunction Switch C2 Turn Signal/Multifunction Switch C3 Page 4192 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Page 12996 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Door Side Hinge Replacement - Rear Door - Door Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the 4 weld locations. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 15417 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Propshaft Speed Sensor - Front Page 8074 Tighten the bolts to 16 N.m (12 lb ft). 15. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the drain plug threads. Install the transfer case drain plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 16. Refill the transfer case with 1.8 L (2 qts) of Auto Trac II Transfer case lubricant, P/N 12378508 (Canadian P/N 10953626). 17. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. Install the fill plug. Tighten Tighten the plug to 27 N.m (20 lb ft). 18. Lower the vehicle. 19. Connect the Tech 2(R) and use SPS reprogramming to reprogram the transfer case control module (TCCM) with TIS software version 11, released October 2002 or newer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15133 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Body - Liftgate Glass Binds/Won't Open Fully Center Mounted Brake Lamp: Customer Interest Body - Liftgate Glass Binds/Won't Open Fully Bulletin No.: 04-08-66-017 Date: November 09, 2004 TECHNICAL Subject: Liftgate or Liftgate Glass Binds, Does Not Open Completely, CHMSL Hits Roof (Remove Material from CHMSL Applique) Models: 2002-2005 Chevrolet TrailBlazer EXT 2002-2005 GMC Envoy XL Condition Some customers may comment that the liftgate or liftgate glass binds when opening or does not open all the way. Cause This condition is caused by the Center High Mounted Stop Lamp (CHMSL) applique hitting the roof of the vehicle. Correction Verify that the CHMSL applique is not loose or broken off one or more of its mounting points. If the applique is broken, it will be necessary to order a replacement part. Important: ^ It should not be necessary to replace the liftgate glass. ^ All measurements and alterations should take place prior to paint finish. ^ It is necessary to install any replacement parts in order to measure to determine if further modification is required. To achieve the proper clearance, modification to the applique is required using the following procedure: 1. Measure (with applique installed) the area of interference in order to determine the material to be removed. ^ The top surface (height) of the applique should line up approximately 1 mm (0.039 in) below the top surface of the roof. ^ A gap of 6-8 mm (0.236-0.315 in) should exist between the roof and the applique to allow for adequate clearance while opening the liftgate. Page 3874 Various symbols are used in order to describe different service operations. Page 7665 Fuse Applications - Underhood Fuse Block Fuse Block: Application and ID Fuse Applications - Underhood Fuse Block Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 14458 Seat Latch: Service and Repair Seat Back Latch Bracket - Rear REMOVAL PROCEDURE 1. Remove the seat back from the vehicle. 2. Remove the bolts (2) that retain the latch bracket to the seat hinge. 3. Remove the latch bracket from the seat hinge. INSTALLATION PROCEDURE 1. Position the latch bracket to the seat hinge. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the latch bracket bolts (2) that retain the latch bracket to the seat hinge. Tighten Tighten the latch bracket bolts to 35 N.m (26 lb ft). 3. Install the seat back to the vehicle. Page 2917 4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Important: Before using trim tool assembly EN 45680-411 the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface. Important: Ensure that the set gage ring EN 45680-412 surfaces are clean. 6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Rearview Mirrors (Outside) - Uncommanded Movement Power Mirror Control Module: All Technical Service Bulletins Rearview Mirrors (Outside) Uncommanded Movement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-008 Date: April, 2002 TECHNICAL Subject: Uncommanded Movement of Outside Rearview Mirrors (Replace Mirror Actuator) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada with Memory Mirrors (RPO D25) Condition Some customers may comment that the outside rearview memory mirrors (RPO D25) may wander or may not go back to a previously set position. This condition may affect both mirrors or only the left or only the right mirror. Cause This condition may be caused by system interaction between the outside rearview mirror(s) and the Driver Door Module and/or the Passenger Door Module. Correction Replace the power mirror actuator(s) on the affected mirror(s) using the following procedure: Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: Under normal conditions, the electrochromic glass in the left outside rearview mirror would not be serviced as described in the Mirror Face Replacement procedure in the Service Manual (SI2000 Document ID # 734660). However, replacing the actuator requires the removal of the mirror glass assembly. The mirror glass should not break following the replacement procedure below but in the event the glass is broken or damaged, the RH glass, P/N 88937195 and/or the LH electrochromic glass, P/N 88494480 may be ordered separately. Replacement of the entire mirror assembly is not required. 1. Manually tilt the top edge of the left mirror glass away from the mirror housing in order to gain access to the upper mirror glass retaining tab. Carefully release the upper glass retaining tab (1) using a flat-bladed tool while simultaneously tilting the mirror glass away from the mirror housing. Refer to the illustration above. Page 13944 Electrical Symbols Part 3 Page 9040 7. Install the park brake cable on the actuator. 8. Depress the retaining clips for the park brake cable. 9. Install the park brake retainer to the frame (left rear shown). Page 7618 For vehicles repaired under warranty, use the table. Disclaimer Page 3166 DISCLAIMER Page 14413 3. Install the cover flaps to the pad with hog rings (1). 4. Install the seat cushion panel on the pad and cover. 5. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 6. Install the pull handle assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). Page 15669 Electrical Symbols Part 7 Page 2808 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 14790 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 393 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10286 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield. 3. Remove the evaporative emission (EVAP) canister from its mounting bracket. Do not disconnect the canister lines. 4. Support the transmission with a transmission jack. 5. Remove the transmission mount to the transmission support retaining nuts. 6. Remove the lower transmission support to the frame mounting bolts. 7. Remove the upper transmission support to the frame mounting bolts. 8. Remove the transmission support from the frame. Installation Procedure Page 12680 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 7972 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9788 C201 Part 2 Page 4412 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 14177 1. Install the head restraint guides by pushing the guides into the frame until the retaining tabs (1) lock the guide in place. 2. Install the seat back cover and pad to the seat back. 3. Install the head restraint. Head Restraint Retractor Assembly Replacement - Rear No. 1 REMOVAL PROCEDURE CAUTION: Refer to Prevent Accidental Deployment of the Head Restraint Retractor Assembly in Service Precautions. 1. Remove the seat back cover and pad. 2. Remove the 3 bolts that retain the head restraint retractor assembly to the seat back frame. Page 9522 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 12671 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 8006 Page 9117 Part 2 of 2 Page 6759 Page 12153 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5232 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Page 13580 34. Install the IP trim pad. 35. Install the windshield garnish moldings. 36. Install the center pillar trim panels. 37. Install the rear side door sill plates. 38. Install the front side door sill plates. 39. Install the rear seats. 40. Install the luggage/cargo shelf assembly, if equipped. 41. Install the cargo net, if equipped. Page 1520 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 4239 Electrical Symbols Part 8 Page 4009 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 8656 case must be ordered through the Technical Assistance Center (TAC) at 1-877446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Go to Transfer Case Replacement. Transfer Case Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the fuel tank shield retaining bolts. 3. Remove the fuel tank shield. 4. Remove the rear propeller shaft. ^ Reference mark the propeller shaft to the rear axle pinion yoke. ^ Remove the bolts and the yoke retainers from the rear axle pinion yoke. ^ Disconnect the propeller shaft from the rear axle pinion yoke. ^ Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case. 5. Drain the transfer case. ^ Remove the drain plug and drain fluid into a suitable container. ^ Install the drain plug. Tighten the plug to 34 Nm (25 lb ft). 6. Remove the front propeller shaft. ^ Reference mark the propeller shaft to the front axle pinion yoke. ^ Remove the bolts and the yoke retainers from the front axle pinion yoke. ^ Disconnect the propeller shaft from the front axle pinion yoke. ^ Remove the propeller shaft from the transfer case. 7. Remove the fuel lines from the retainer. 8. Remove the electrical harness from the retainers. 9. Remove the electrical connector from the speed sensors. 10. Remove the motor/encoder electrical connector. 11. Remove the transfer case wiring harness. 12. Remove the vent hose. 13. Install a transmission jack for the transfer case. 14. Remove the transfer case mounting nuts. 15. Remove the transfer case from the vehicle. 16. Remove the transfer case gasket. Installation Procedure Important: DO NOT use silicone sealant in place or with the transfer case gasket. 1. Replace the transfer case gasket. Page 260 Page 2590 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 1581 DISCLAIMER Page 6209 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 9049 1. Install the park brake lever assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the right front park brake lever retaining nut. ^ Tighten the park brake lever mounting nut to 25 Nm (18 ft. lbs.). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Raise the vehicle. 5. Connect the park brake cables to the equalizer. 6. Lower the vehicle. 7. Install the floor console. 8. Enable the park brake automatic adjuster. Page 2828 Disclaimer Page 14272 Seat Lumbar Motors And Position Sensors Assembly - Driver Page 4541 Body Control Module: Removal and Replacement Body Control Module Replacement REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If replacing the BCM on a Chevrolet Trailblazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet Trailblazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 13775 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Page 4576 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 7863 Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation. 1. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install motor/encoder mounting bolts to the transfer case. Tighten Tighten the bolts to 16 Nm (12 lb ft). 3. Install the motor/encoder electrical connector. 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 9512 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 1486 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: - Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the CKP sensor into the engine block. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. A/C - Clicking Noises From The Instrument Panel Air Door Actuator / Motor: Customer Interest A/C - Clicking Noises From The Instrument Panel Bulletin No.: 04-01-38-002 Date: January 22, 2004 TECHNICAL Subject: Clicking Noise From Instrument Panel After Vehicle is Started (Replace HVAC Mode Actuator) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition Some customers may comment on a clicking noise coming from the instrument panel after the vehicle is started. Cause This concern may be caused by an internal failure in the HVAC (heating, ventilation and air conditioning) mode door actuator. Correction Technicians are to replace the HVAC mode door actuator with an updated design part as listed below. Refer to the Mode Actuator Replacement procedure in the HVAC section of SI. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 15321 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 12456 Labor Time Information Page 9808 C401 (Long Wheelbase, Body Type VIN 6) Park Brake Cable Replacement Parking Brake Cable: Service and Repair Park Brake Cable Replacement Park Brake Cable Replacement Removal Procedure Notice: Handling the parking brake cables during service requires extra care. Damage to the nylon coating reduces the corrosion protection. If the damage area passes through the nylon coating, increased parking brake effort could result. Avoid contacting the protective coating with sharp-edge tools or the sharp surfaces of the vehicle underbody. 1. Disable the park brake automatic adjuster. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the rear propeller shaft. 4. Remove the park brake cables from the parking brake equalizer. 5. Remove the park brake cables from the retainer. Important: When serving the left park brake cable, the fuel tank DOES NOT have to be removed. Page 11830 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 7568 12. Install the new gasket assembly. 13. Inspect the positioning of the gasket and the motor shaft. If necessary to align them as shown, perform the following steps. ^ Connect a fused jumper to the transfer case encoder motor connector red wire and the other end to a positive battery terminal. ^ Connect another jumper to the transfer case encoder motor connector black wire and momentarily touch the other end of this wire to the ground terminal of a battery. This will cause the motor shaft to turn to allow alignment as shown. Important: Inspect the encoder motor attachment face for the presence of the two (2) locating sleeves. If missing from the encoder motor, they need to be retrieved from the transfer case and reinstalled into the encoder motor before installation. 14. Position the motor to the transfer case and install the retainers. Tighten Page 9321 Equivalents - Decimal And Metric Part 1 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Front Axle Actuator Page 14807 Brake Warning Indicator: Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Page 13520 Disclaimer Page 4150 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 6091 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 11047 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 3132 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 11913 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 4191 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Sleeves 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10450 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the spare tire carrier. 3. Remove spare wheel hoist assembly mounting bolts from the frame. 4. Remove the spare wheel hoist assembly from the vehicle. Installation Procedure 1. Install the spare wheel hoist assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install spare wheel hoist assembly mounting bolts to the frame Tighten the spare wheel hoist assembly mounting bolts to the frame to 50 Nm (37 inch lbs.). 3. Install the spare tire to the spare tire carrier. 4. Lower the vehicle. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 740 Electrical Symbols Part 8 Page 3004 6. Remove the air pressure to the cylinder. 7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil. 8. Install the camshafts to their original position. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the camshaft caps onto their original journal. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 12. Install the spark plugs. Page 15735 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 12569 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 14153 Sunroof / Moonroof Module: Diagrams Sunroof Module Connector C1 Sunroof Module Connector C2 Page 15731 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 7076 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 12059 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 9012 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Apply the parking brake and block the wheels. 2. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Install the rubber plugs the brake pipe ends. 4. Remove the master cylinder nuts and bolts. 5. Remove the master cylinder from the vehicle. 6. Drain the master cylinder reservoir of all the brake fluid. 7. Remove the reservoir from the master cylinder, if needed. Page 15132 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 9015 Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the master cylinder bolts and nuts Tighten Tighten the nuts to 36 N.m (27 lb ft). 6. Remove the rubber plugs from the brake lines 7. Connect the brake pipes to the master cylinder. Tighten Tighten the pipe nuts to 30 N.m (22 lb ft). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. Page 15318 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Page 7970 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Page 1706 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Locations Locations View Page 1454 Electrical Symbols Part 8 Page 13155 2. Position the latch to the previously marked location on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts which retain the latch to the mounting bracket. Tighten the bolts to 10 N.m (89 lb ft). 4. Inspect the latch for proper operation before closing the hood. 5. Check the alignment of the latch to the hood striker. Adjust the latch if necessary. Refer to Hood Latch Adjustment. 6. Install the grille. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 1620 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 15914 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 5109 Crankshaft Position (CKP) Sensor Page 4654 Splice Pack SP205 Page 5817 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Locations Locations View Page 5266 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 15980 Electrical Symbols Part 8 Page 7557 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 8318 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 15475 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: All Technical Service Bulletins Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 3679 Electrical Symbols Part 8 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 12688 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 259 Specifications Transmission Position Switch/Sensor: Specifications Park/Neutral Position Switch Screw ........................................................................................................................................................ 3 Nm (27 inch lbs.) Engine - New Cylinder Bore Sleeve Replacement Procedure Cylinder Liner: Technical Service Bulletins Engine - New Cylinder Bore Sleeve Replacement Procedure Bulletin No.: 04-06-01-022B Date: October 24, 2005 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer 2004-2006 Chevrolet Colorado 2002-2006 GMC Envoy 2004-2006 GMC Canyon 2002-2004 Oldsmobile Bravada with 2.8L, 3.5L or 4.2L Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Supercede: This bulletin is being revised to update model years, bulletin content, add parts information and the tool part number in the Warranty information and the Cylinder Sleeve Trimming/Trim Tool Cutter information. Please discard Corporate Bulletin Number 04-06-01-022A (Section 06 Engine/Propulsion System). A new procedure has been developed to replace the cylinder bore sleeves in the 2.8L, 3.5L and 4.2L engines. This procedure has been added to the Service Manual in the Engine Mechanical sub-section. This procedure may be used when the engine is in or out of the vehicle. Cylinder Bore Sleeve Removal Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. Locations Locations View Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 2591 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 6780 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 8853 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. A/C - Clicking Noises From The Instrument Panel Air Door Actuator / Motor: All Technical Service Bulletins A/C - Clicking Noises From The Instrument Panel Bulletin No.: 04-01-38-002 Date: January 22, 2004 TECHNICAL Subject: Clicking Noise From Instrument Panel After Vehicle is Started (Replace HVAC Mode Actuator) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada Condition Some customers may comment on a clicking noise coming from the instrument panel after the vehicle is started. Cause This concern may be caused by an internal failure in the HVAC (heating, ventilation and air conditioning) mode door actuator. Correction Technicians are to replace the HVAC mode door actuator with an updated design part as listed below. Refer to the Mode Actuator Replacement procedure in the HVAC section of SI. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 12233 Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 13227 Optimal results will be obtained by allowing the seal to remain in a compressed state with the glass closed for a period of 48 hours. Parts Information Parts are expected to be available from GMSPO on June 13, 2003. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: All Technical Service Bulletins Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 528 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. Service and Repair Dome Lamp Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Carefully grasp the sides of the lens to partially expose the rear retaining tab. 2. Use a flat bladed tool in order to release the rear lens retaining tab. 3. Lower the rear edge of the lens away from the headliner. 4. Move the lens rearward in order to release the front horizontal retaining tab. 5. Remove the lens from the headliner. Body - Liftgate Glass Unlatches On Bumpy Roads Tailgate Latch: All Technical Service Bulletins Body - Liftgate Glass Unlatches On Bumpy Roads Bulletin No.: 04-08-66-004A Date: June 22, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Liftgate Glass Unlatches on Rough/Bumpy Road Surfaces (Replace Liftgate Window Latch) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to provide the correction and warranty information, which is now available for Advanced Service Bulletin Number 04-08-66-004. Please discard Corporate Bulletin Number 04-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear liftgate window unlatches when driving on rough/bumpy road surfaces. This condition may be very difficult to duplicate. Cause The liftgate window latch may be the cause of this condition. Correction Replace the liftgate window latch. Refer to the Liftgate Window Latch Replacement procedure in the Body Rear End sub-section of the Service Manual. Part Information Parts are expected to be available from GMSPO on June 25, 2004. Warranty Information For vehicles repaired under warranty, use the table. Page 5046 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5320 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Front Suspension Control Arm: Service and Repair Front Suspension Lower Control Arm Bracket Replacement Lower Control Arm Bracket Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft link lower retaining nut. 4. Disconnect the stabilizer shaft link and washer from the lower control arm. 5. Remove the lower control arm to lower control arm bracket mounting nuts. Important: Note the direction the bolts are removed for reinstallation. 6. Remove the lower control arm to lower control arm bracket mounting bolts. Important: Take care not to disengage the axle shaft from the transmission. Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Drivetrain - Differential Carrier Replacement Update Differential Carrier: Technical Service Bulletins Drivetrain - Differential Carrier Replacement Update File In Section: 04 - Driveline Axle Bulletin No.: 02-04-19-001 Date: December, 2002 SERVICE MANUAL UPDATE Subject: Revised Differential Carrier Assembly Replacement Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada This bulletin is being issued to revise the Differential Carrier Assembly Replacement Procedure in the Front Drive Axle sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Removal Procedure 1. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Page 12054 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 8828 Electrical Symbols Part 3 Page 10722 Locations View - HVAC Systems - Automatic Page 14824 Electrical Symbols Part 1 Page 10662 1. Remove the I/P carrier. 2. Disconnect the electrical connector from the mode actuator. 3. Remove the screws from the mode actuator (3). 4. Remove the mode actuator. INSTALLATION PROCEDURE 1. Install the mode actuator (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator (3). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the mode actuator electrical connector. 4. Install the I/P carrier. 5. Calibrate the air temperature actuator on vehicles equipped with automatic climate control (C68). Refer to Re-Calibrating Actuators (Primary) or Re-Calibrating Actuators (Auxiliary HVAC). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Mode Actuator - Auxiliary REMOVAL PROCEDURE M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Page 7604 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 44 Page 1236 Air Temperature Sensor Assembly - Inside Page 3949 Electrical Symbols Part 6 Page 4485 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-965 Page 1809 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 12249 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... ................................................ 140 Nm (103 ft. lbs.) Page 6220 5. Using the J-35616-5, attach the RED lead from the other jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 6. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 7. Touch the battery terminals of the second 9-volt battery to the battery terminals of the second jumper harness. This will rotate the encoder motor ( actuator) shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 8. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the reference lines as shown in the picture. This orientates the encoder motor (actuator) to NETURAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 9. Wiggle the control actuator lever shaft of the transfer case by hand to find the low point of the cam. 10. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. 11. After installation, the transfer case will perform a learn procedure upon a requested MODE change. Parts Information For warranty claims, submit batteries as parts. Page 11480 26. Remove the seat belt upper bracket and retractor assembly from the seat. 27. Install the new seat belt retractor and original bracket on the seat back frame. 28. Apply threadlocker to the upper retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 29. Install the push-in fastener to attach the retractor to the seat back frame. 30. Apply threadlocker to the lower retractor bolt and install. Tighten Tighten the bolt to 55 Nm (40 lb ft). 31. Install the seat belt webbing material into the slot in the upper bracket. 32. Install the seat back panel and four push-in fasteners. 33. Reposition the pad and cover. 34. If equipped, connect the seat back heating element electrical connector. 35. Position the seat back cover over the top of the seat back and begin pulling it down over the seat back. 36. Position and install the seat back cover around the side impact air bag module. 37. Install the head restraint retainers. 38. Install the head restraint. 39. Install the push pins that secure the bottom of the seat back cover to the seat back frame. 40. Connect the J-strip at the bottom of the seat cover. 41. Install the seat belt bezel to the seat belt material, position on the top of the seat back and install the attaching screw. Tighten Tighten the screw to 6 Nm (53 lb in). 42. Install the seat belt anchor and nut to the seat adjuster. Tighten Tighten the nut to 52 Nm (38 lb ft). 43. Install the outer trim panel to the side of the seat cushion and install the screws. Tighten Page 15449 Electrical Symbols Part 2 Page 4080 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Page 9586 43. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 44. Turn the key OFF. Remove the key. 45. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 46. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 47. Reinstall the rear electrical center cover. 48. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 49. Reinstall the knee bolster (TrailBlazer). 50. Reinstall the closeout/insulator panel (TrailBlazer). 51. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 52. Reinstall the console to the vehicle and install the retainers. 53. Reinstall the shift boot and handle assembly. 54. Reinstall the console bin and retainers. 55. Reinstall the first lock pillar trim and carpet retainers to both door openings. 56. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 57. Install the IP upper trim panel and windshield pillar moldings. 58. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 59. Connect the Tech 2(R) and clear codes. Non Bose(R) Radios With Rear Audio Controls These vehicles use wiring harness P/N 15164933. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 4. Disconnect the wires from the driver's seat and remove the driver's seat. 5. Disconnect the negative battery cable. 6. Remove the left rear seat cushion and the back rest assemblies. 7. Remove the jack handle tool support assembly. Page 9700 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 11666 Electrical Symbols Part 1 Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 8829 Electrical Symbols Part 4 Page 9553 38. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 39. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 40. Reinstall the rear electrical center cover. 41. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate, and install the retainers. 42. Reinstall the knee bolster (TrailBlazer). 43. Reinstall the left side closeout/insulator panel (TrailBlazer). 44. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 45. Reinstall the console to the vehicle and install the retainers. 46. Reinstall the shift boot and handle assembly. 47. Reinstall the console bin and retainers. 48. Reinstall the first lock pillar trim and carpet retainers to both door openin9s. 49. Position the drivers seat assembly in the vehicle. Connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). 50. Reinstall the SIR fuse # 18 in the underhood electrical center and close the hood. 51. Connect the Tech 2(R) and clear codes. Page 5745 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Page 6047 Equivalents - Decimal And Metric Part 1 Page 5585 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 9584 58. Install the IP upper trim panel and windshield pillar moldings. 59. Reinstall the SIR fuse #18 in the underhood electrical center and close the hood. 60. Connect the Tech 2(R) and clear codes. Bose(R) Premium Sound Without Rear Audio Controls These vehicles use wiring harness P/N 15164931, which you will modify slightly by cutting some unused wires. 1. Remove the key from the lock cylinder. 2. Remove the SIR fuse # 18 from the underhood electrical center. 3. Remove the windshield pillar trim from both windshield pillars. 4. Remove the upper IP closeout panel. 5. Remove both front upper IP panel speakers. 6. Disconnect the wires from both speakers. Cut the green connectors from the speaker wires as far up under the IP as possible. 7. Remove the retainers that secure the driver's seat assembly to the floor of the vehicle. 8. Disconnect the wires from the driver's seat and remove the driver's seat. 9. Disconnect the negative battery cable. 10. Remove the left rear seat cushion and the back rest assemblies. 11. Remove the jack handle tool support assembly. 12. Loosen the rear electrical center from the floor of the vehicle. 13. Separate the rear electrical center from its mounting bracket. 14. Remove the left side front and rear door opening carpet retainers and the left side first lock pillar trim. 15. Remove the six retaining screws from the console compartment bin and remove the bin. 16. Remove the shift lever handle and boot assembly. 17. Remove the screws that retain the console to the floor of the vehicle. 18. Set the parking brake as firmly as possible, depress the Auto Trans Shift Lock Control solenoid plunger and shift the transmission shift lever to the L1 position. 19. Lift the console, disconnect the console wiring and remove the console from the vehicle. 20. Remove the left side closeout/insulator panel (TrailBlazer only). 21. Remove the left side knee bolster (TrailBlazer only). 22. Remove the screws retaining the IP bezel to the IP, and remove the bezel (TrailBlazer only). 23. Remove the screws retaining the carpet panel to the lower IP center control panel pedestal (except TrailBlazer). 24. Remove the screws that retain the IP center trim panel to the IP, loosen the trim panel, disconnect the wiring and remove the trim panel from the vehicle (except TrailBlazer). 25. Remove the radio retaining screws, pull the radio forward and disconnect all connectors. 26. Unwrap/cut the white tape on the new speaker wiring harness to spread out the wiring harness. Important: Page 9827 Locations View Page 12177 Speaker: Connector Views Speaker - LF Door Speaker - LR Door Page 7478 ^ Tighten the front propeller shaft yoke clamp bolts to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Page 5889 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 1118 3. Install the switch bezel to the seat with the 3 screws. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE Page 10997 4. Connect the heater hoses to the heater core. 5. Connect the evaporator tube (4) to the evaporator (1). 6. Install the accumulator (6) to the evaporator (1). NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the accumulator retaining nut. Tighten Tighten the nut to 4.5 N.m (40 lb in). 8. Install the I/P carrier. 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400. 11. Refill the engine coolant. Service and Repair Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Lift Gate Removal Procedure 1. Remove the liftgate latch assembly from the liftgate. 2. Place the latch assembly on a clean, prepared surface. 3. Remove the 2 screws (2) that retain the lock actuator (1) to the latch assembly. 4. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. Installation Procedure 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 5744 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 13479 Disclaimer Page 11683 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Electrical - Proper Jump Starting Procedure Jump Starting: Technical Service Bulletins Electrical - Proper Jump Starting Procedure Bulletin No.: 04-06-03-005A Date: May 17, 2006 INFORMATION Subject: Proper Connection Information to Avoid Blown 125 Amp Fuse and Various Interior Electrical System Conditions When Jump Starting Vehicle Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2007 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-06-03-005 (Section 06 - Engine/Propulsion System). It has been found that some dealers may be using the IP battery positive stud at the underhood fuse block to jump start the vehicle. This bulletin is being issued to inform dealers that investigation has indicated the 125 amp mega fuse (no. 48) located in the engine compartment fuse block may be blown resulting in various electrical system conditions due to using this improper connection. To properly jump start the vehicle, you must always use the following connections. For the positive connection, use the battery terminal. For the negative connection, use the remote terminal located on the front engine lift bracket (marked "GND"). Page 1989 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 12312 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 2337 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14750 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Page 8079 6.2. Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. 6.3. Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing on the finger section of the J 45380. ^ Install the finger section of the J 45380. ^ Position the bushing and the tool to the case. ^ Using a hammer and J 45380, install the bushing. 2. Using the appropriate seal installer, install the rear output shaft seal in the transfer case. 3. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Verify the fluid level. Refer to Transfer Case Fluid Replacement. 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 6. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6437 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Recall 04V201000: Possible Seat Belt Sensor Malfunction Seat Belt: Recalls Recall 04V201000: Possible Seat Belt Sensor Malfunction DEFECT: Certain sport utility vehicles do not conform to Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." One of the two sensors in the driver's and front passenger's seat belt retractor could be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as heavy braking, may not operate as intended. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of an injury. Remedy: Dealers will inspect the seat belt assemblies to determine proper vehicle sensor function. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Oldsmobile at 1-800-630-6537.. Page 2069 5.1. Push out the two "single" locking tabs (two lower arrows in illustration above) located on the underside of the housing (motor end). 5.2. At the other end of the gasket/cover plate, place a flathead screwdriver tip (1) between the gasket/cover plate and the motor housing near the "dual" locking tabs. Twist the screwdriver clockwise/counterclockwise at both sides until the locking tabs break and the gasket/cover plate comes off. 5.3. Discard the gasket/cover plate. 6. Avoiding the wire connection, take two small flathead screwdrivers (one on each side of the encoder) and rock the encoder sensor out using light pressure on each screwdriver. 7. Gently remove the encoder sensor from the wire harness connector. Pry these apart by inserting a small flathead screwdriver between the terminals and the harness connector. Verify that no damage or corrosion exists on either male encoder terminals or female wiring harness terminals. 8. Install the new encoder sensor by connecting to the harness and then gently sliding the encoder sensor over the motor shaft. The hex feature (3) on the encoder should face down toward the motor housing. Make sure the tab (1) on the encoder mates with the notch (2) on the shaft. If the encoder tab is not aligned with the output shaft, rotate the encoder inner ring by hand to mate properly. Press the encoder fully onto the shaft and into the housing. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 15461 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 13199 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the module to the liftgate. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. Page 1782 Electrical Symbols Part 2 Page 15766 Electrical Symbols Part 8 Page 4226 Accelerator Pedal Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Page 8966 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 150 Nm (110 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 3853 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector. ^ Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or Page 8333 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 9298 Electrical Symbols Part 8 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Page 10116 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Description and Operation Oil Change Reminder Lamp: Description and Operation WHEN TO CHANGE ENGINE OIL Your vehicle has a computer that lets you know when to change your engine oil. This is not based on mileage, but on engine revolutions and engine operating temperature. When the computer has calculated that the oil needs changing, the GM Oil Life System will indicate that a change is necessary. The mileage between oil and filter changes will vary depending on how you drive your vehicle - usually between 3,000 miles (5,000 km) and 12,000 miles (20,000 km) since your last oil and filter change. Under severe conditions, the system may come on before 3,000 miles (5,000 km). Never drive your vehicle more then 12,000 miles (20,000 km) or 12 months (whichever occurs first) without an oil change. The system won't detect dust in the oil. So if you drive in a dusty area, be sure to change your oil and filter every 3,000 miles (5,000 km) or sooner. Page 9369 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood C1 Page 2043 Page 1598 Electrical Symbols Part 7 Page 14949 Equivalents - Decimal And Metric Part 1 Page 1211 Locations View - HVAC Systems - Automatic Page 5025 Electrical Symbols Part 4 Page 15472 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3983 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Intake Air Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Diagrams Intake Air Temperature Sensor Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Page 8856 Equivalents - Decimal And Metric Part 1 Page 16071 Parts are currently available from GMSPO. Disclaimer Powertrain Control Module (PCM) Replacement Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector retaining bolts (1) in the center of the PCM harness connectors. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Remove the PCM harness connectors (3) from the PCM (2). 3. Remove the PCM mounting nuts and bolts (3). NOTE: Refer to PCM and ESD Notice in Service Precautions. 4. Remove the PCM (2) from the intake manifold. 5. Remove the PCM mounting studs (1) from the intake manifold, if necessary. Page 13634 9. Release the five screws that retain the rear quarter trim panel to the body. 10. Remove the rear quarter trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary power outlet to the trim panel. 2. Position the trim panel to the vehicle. Locations Page 5620 Page 3559 For vehicles repaired under warranty, use the table. Disclaimer Page 15666 Electrical Symbols Part 4 Page 12992 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill only through the hinge base (1). Do not drill through the mating surface (2). 6. At each punch location, drill a 3-mm (1/8-in) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19-mm (3/4-in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 7119 Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment Adjustment Procedure 1. Ensure that the range selector cable is not restricted. 2. Ensure that the floor shift control is in the PARK position. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the range selector cable (4) from the range selector lever ball stud (6). 5. Ensure that the range selector lever is in the mechanical PARK position. (Rotate the range selector lever fully clockwise). 6. Release the locking tab (2) and slide the secondary lock cover (1) to the side. 7. Carefully squeeze the locking tabs (1) together to disengage the primary lock. A/C Refrigerant System Oil Charge Replenishing Refrigerant Oil: Service and Repair A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (fart). Page 5545 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. CAUTION: Wear safety glasses when using compressed air in order to prevent eye Injury. 2. Using compressed air, blow any dirt out of the quick-connect fining. 3. Squeeze the plastic retainer release tabs. 4. Pull the connection apart. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-ring located in the female connector will swell and may prevent proper reconnection if not lubricated. Page 3370 Disclaimer Fuse Block - Rear Locations View Page 5916 Ignition Coil 3 Ignition Coil 4 Page 6000 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 12502 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Locations Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 1504 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Page 10160 For vehicles repaired under warranty, use the table. Disclaimer Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Recall 01V334000: Transfer Case Control Module Update Control Module: Recalls Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... ................................................ 140 Nm (103 ft. lbs.) Page 5331 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices-in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping tool ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Page 1623 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 11185 Solar Sensor: Description and Operation SUNLOAD SENSOR The sunload sensor is a 2 wire photo diode. The vehicle uses left and right sunload sensors. The two sensors are integrated into the sunload sensor assembly. Low reference and signal circuits enable the sensor to operate. As the light shining upon the sensor gets brighter, the sensor resistance increases. The sensor signal decreases as the resistance increases. The sensor operates within an intensity range between completely dark and bright. The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between 0-255 counts. The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted sunload value. This value will not be displayed on the scan tool. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is fixed. The scan tool parameter for the sunload sensor is the actual state of the signal circuit. Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Page 10278 5. Remove the rear axle support. 6. Install the wheelhouse panel. 7. Install the tire and wheel. 8. Lower the vehicle. Rear Axle Lower Control Arm Replacement Rear Axle Lower Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Raise and support the rear axle at the designed D - height. 3. If equipped with air suspension, Repressurize the air suspension system. 4. Remove the rear axle lower control arm to the axle mounting nut and bolt. 5. Remove the rear axle lower control arm to the frame mounting nut and bolt. 6. Remove the lower control arm. Page 7450 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7801 2. Connect the transfer case front speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Body - Front Bumper Fascia Panel Wavy Front Bumper Cover / Fascia: Customer Interest Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi Page 13016 Page 8666 Page 5414 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the APP sensor retaining fasteners (1). Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 14732 Electrical Symbols Part 1 Page 8915 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Page 8483 ^ (1) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from the jumper harness to the Motor Control B terminal (pin E - wire color red) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Motor Control A terminal (pin D - wire color black) of the transfer case encoder motor (actuator) wiring harness connector. 4. Touch the battery terminals of the 9-volt battery to the battery terminals of the jumper harness. This will rotate the encoder motor shaft in either a clockwise or counterclockwise rotation depending on battery orientation. 5. Using the 9-volt battery, rotate the encoder motor (actuator) shaft until the keyway on the motor shaft is between the two reference lines as shown in the picture. This orientates the encoder motor (actuator) to NEUTRAL for ease of assembly. Note: If available, another option is to rotate the encoder motor (actuator) shaft until a shipping plug from a new encoder motor (actuator) can be installed. 6. Install the encoder motor (actuator) on the control actuator lever shaft of the transfer case. NVG 226 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (4) J-356165 Terminal Test Adapter (Test Probe) ^ (2) 9 Volt Battery (obtain locally) 1. Remove the encoder motor (actuator) from the transfer case. 2. Using the J-35616-5, attach the RED lead from one of the jumper harnesses to the Battery Positive Voltage terminal (pin F - wire color orange) of the transfer case encoder motor (actuator) wiring harness connector. 3. Using the J-35616-5, attach the BLACK lead from the jumper harness to the Lock Solenoid Control terminal (pin G - wire color tan) of the transfer case encoder motor (actuator) wiring harness connector. 4. Attach a 9-volt battery to this harness. You will hear the encoder motor (actuator) unlock. Page 1905 6. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. Tighten Tighten the front end discriminating sensor bolts to 8 N.m (71 lb in). 7. Position the headlamp wire harness (1) to the retaining clip. Page 15348 Tachometer: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a diagnostic aid as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Page 5931 Electrical Symbols Part 5 Page 1479 Various symbols are used in order to describe different service operations. Page 9831 Relay Box: Application and ID Fuse Block - Underhood Fuse Block-Underhood (Six Cylinder Engine, 4.2L) Page 4589 Camshaft Position Sensor: Description and Operation The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 2365 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 12162 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection-Fuses ^ Circuit Protection-Circuit Breakers ^ Circuit Protection-Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Service and Repair Power Steering Fluid Reservoir: Service and Repair "For information regarding this component please refer to power steering pump service and repair" Page 2220 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 240 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 8710 2. Install the control switch in the bezel cover. Important: Ensure that the bezel cover is properly seated before installing the trim screws. 3. Install the bezel cover. Brakes - Revised Caliper Mounting Bolt Torque Spec. Brake Caliper: Technical Service Bulletins Brakes - Revised Caliper Mounting Bolt Torque Spec. Bulletin No.: 03-05-23-002A Date: April 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Brake Caliper Bracket Mounting Bolt Fastener Tightening Specification Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2004-2005 Chevrolet SSR 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add models, model years and update the fastener tightening specification. Please discard Corporate Bulletin Number 03-05-23-002 (Section 05 - Brakes). This bulletin is being issued to revise the front brake caliper bracket mounting bolt fastener tightening specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct fastener tightening specification for the front brake caliper bracket mounting bolt is 150 N.m (110 lb ft). Disclaimer Locations Locations View Page 12415 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 12144 Electrical Symbols Part 2 Page 126 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 14969 Electrical Symbols Part 8 Page 4989 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 14378 6. Remove the SIR electrical harness (2) from the seat pan. 7. Remove the seat electrical harness from the seat pan. 8. Remove the wire harness fasteners from the seat pan. 9. Disconnect the seat cushion heater electrical connector, if equipped. IMPORTANT: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the seat pad. 10. Separate the hook and loop retaining strips. 11. Remove the hog rings (1) from the bottom rear side of the cover. 12. Remove the 11 hog rings from the top side of the cover. 13. Remove the seat cushion trim cover and pad from the seat frame. Engine Controls - MIL ON/Delayed Downshift/Fan Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Delayed Downshift/Fan Noise File In Section: 06 - Engine/propulsion System Bulletin No.: 01-06-04-052B Date: May, 2004 OBD SOFTWARE UPGRADE Subject: On-Board Diagnostic (OBD) System Improvements - Service Engine Soon Light On, DTC P0014, P0116 or P1683 Set, Delayed Transmission Downshift and/or Excessive Fan Noise, ID # YT04032 (Reprogram PCM) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Inline 6-Cylinder Engine (VIN S - RPO LL8) This bulletin is being revised to add an ID # to the Subject line and to change the labor code in the Warranty Information. Please discard Corporate Bulletin Number 01-06-04-052A (Section 06 Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on the Service Engine Soon lamp being illuminated, a delayed transmission downshift and/or excessive fan noise. Upon investigation, the technician may find either a DTC P0014 (Cam Phaser Performance), DTC P0116 (High Sided Coolant Rationality) and/or DTC P1683 (Low Power Counter Failure). Correction Reprogram the powertrain control module (PCM) on all affected vehicles, as identified above, including vehicles in new dealer inventory, used inventory, and any that return for service in or out of warranty. Using a Tech 2 scan tool and TIS 2000, verify that the calibration programmed into the vehicle's PCM has been programmed since August, 2001 or later. The GM Vehicle Inquiry System (GM VIS) may also be checked to see if the vehicle has been programmed since August, 2001. If the August, 2001 or later updated calibration has not been installed, reprogram the PCM with the latest updated calibration from TIS 2000 version 8.5 for 2001 data update or later. Warranty Information For vehicles repaired under warranty, use the table. *This a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide. Page 1619 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Page 15524 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Page 3988 Engine Coolant Temperature (ECT) Sensor Page 1597 Electrical Symbols Part 6 Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 121 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 9226 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Gear Sensor/Switch: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 8090 Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors. CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) Page 8817 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 11963 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 9294 Electrical Symbols Part 4 Page 341 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation A/T - Slipping/Missed Shifts Diagnostic Tips Shift Cable: Technical Service Bulletins A/T - Slipping/Missed Shifts Diagnostic Tips File In Section: 07 - Transmission/Transaxle Bulletin No.: 01-07-30-043 Date: December, 2001 INFORMATION Subject: Diagnostic Tips for Slipping or Missing Second, Third and/or Fourth Gear Models: 2001-2002 Chevrolet Camaro, Corvette 2001-2002 Pontiac Firebird 2001-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Suburban, Tahoe, Yukon, Yukon XL) 2001-2002 Chevrolet and GMC G-Van Models (Express, Savana) 2001-2002 Chevrolet and GMC M/L-Van Models (Astro, Safari) 2001-2002 Chevrolet and GMC S/T Pickup and Utility Models (S10, Sonoma, Blazer, Jimmy) 2002 Chevrolet and GMC S/T Utility Models (New Style) (TrailBlazer, Envoy) 2002 Cadillac Escalade 2001-2002 Oldsmobile Bravada Recently, a study was completed to determine the causes of slipping/missing 2nd, 3rd or 4th gear in the 4L60/4L65-E transmission family. This study was conducted using transmissions which were determined by dealership technicians as having a slipping/missing shift. The transmissions used were from vehicles with less than 19,000 km (12,000 mi) and the slipping/missing shift condition was verified during a test drive by dealership personnel before the transmission was removed from the vehicle. Eight items were found to cause the majority of the slipping/missing shift concerns. These eight items are listed below in the order of frequency that they were found. ^ Chips in the servo feed oil passage, orifice # 7 in the spacer plate. ^ Cut forward clutch piston inner seal. ^ Cut 3/4 clutch piston outer seal. ^ Input housing orifice cup plug blown out. ^ Input housing cracked or broken. ^ Mislocated valve body to spacer plate check ball(s). ^ Case damaged at the 2nd clutch apply piston pin bore causing the pin to drag/stick in the bore. ^ Input housing air bleed orifice cup plug with a check ball that does not seal. In addition to the above items, a misadjusted shift cable has been found to cause these types of concerns. When attempting to correct a slipping/missing second, third or fourth gear, the items listed above should be inspected as possible causes. It is also important to reference the appropriate Service Information for additional possible causes of these concerns. Disclaimer Page 3103 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Page 13995 2. Partially remove the mirror glass from the mirror housing. 3. Disconnect the two mirror heater wires (2) from the mirror glass while holding down the terminals on the glass. The terminals may pull off the mirror glass it they are not held in place. Unclip the electrochromic mirror wire harness connector (3) from the back of the mirror glass and disconnect it. Refer to the illustration above. 4. Remove the mirror glass from the mirror assembly. 5. Remove the three mirror actuator retaining screws (4) using a size Ti 0 TORX® driver. Refer to the illustration above for locations. 6. Remove the actuator assembly from the mirror housing. 7. Disconnect the two electrical connectors from the mirror actuator. 8. Remove the mirror actuator from the mirror assembly. 9. Connect the two electrical connectors to the new mirror actuator. 10. Install the actuator into the mirror housing using the three T10 TORX(R) head retaining screws. Page 513 Part 2 of 2 Engine - Oil Leak at Oil Pressure Switch Oil Pressure Sender: Customer Interest Engine - Oil Leak at Oil Pressure Switch File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-033 Date: October, 2002 TECHNICAL Subject: Oil Leak at Oil Pressure Switch (Apply Sealant) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment about oil spots on the driveway or an apparent oil leak. Upon investigation, the technician may find that the leak is coming from the area of the oil pressure switch. Cause The cause of this condition may be due to an incorrect type or application of sealant. Correction Remove and re-install sensor with new thread sealant. When re-installing an existing sensor or installing a new replacement sensor, the technician should be sure that the threads are clean and dry. Apply sealant to the threads in the following manner: ^ Apply a consistent coating across at least three full threads. ^ Do not apply any sealant to the first full thread. ^ Do not apply any sealant in the area of the 0-ring seal. Notice: Failure to properly apply thread sealant may lead to repeat leaks or the failure of the oil pressure switch. Parts Information Parts are currently available from GMSPO. Warranty Information Page 15025 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and Canada Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter shown in this bulletin). Customer Notification - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the suggested dealer letter. Dealer Program Responsibility - All All unsold new vehicles in dealers' possession and subject to this program MUST be held and inspected/repaired per the service procedure of this program bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 1112 Seat Adjuster Switch - Passenger (W/O Memory Seat) Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Front The content of this article reflects the changes identified in TSB 03-05-23-002A Brake Rotor Replacement - Front Removal Procedure ^ Tools Required J 42450-A Wheel Hub Cleaning Kit 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, using a appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 282 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 10114 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 5412 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 6050 Conversion - English/Metric Lighting - Tail Lamp(s) Inoperative Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Retractor Jamming Prevention Bulletin No.: 03-09-40-006B Date: December 02, 2005 INFORMATION Subject: Information on Avoiding Front Seat Belt Retractor Jamming When Storing Seat Belt Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and Saab 9-7X models. Please discard Corporate Bulletin Number 03-09-40-006A (Section 09 - Restraints). This bulletin is being issued to provide information to the customers if they comment that the left or right front seat belt may appear to not release from the retractor when trying to put on the seat belt. A Description For Your Customer This condition generally does not require replacement of any parts. This condition is the result of allowing the belt to enter the retractor at a high rate of speed. If the belt is allowed to go all the way back into the retractor very quickly, it is possible that the force of the belt stopping suddenly against the seat back will vibrate the retractor. This vibration "fools" the retractor into thinking that the vehicle is changing velocity. The normal function of the retractor under this condition is to lock the belt. How to Correct or Eliminate the Condition The only way to completely eliminate the condition is not to allow the belt to retract back all the way into the retractor quickly. The fast retraction usually occurs when the customer holds the latch while unbuckling and guides the webbing into the retractor quickly until it's fully stowed. As long as the customer guides the belt at a slower rate of speed, the retractor will work consistently without locking. Also, if the customer unbuckles the belt and lets the webbing retract on its own (without guiding it), there is generally enough friction from the belt against clothing to slow down the belt so it won't lock when it fully stows. If the customer does allow the belt and latch plate to retract quickly, the retractor can easily be restored to normal operation. Simply pull on the belt to create some slack in the webbing and pay back some of the webbing into the retractor. Slack can also be created by pushing on the foam at the top of the seat back. After a maximum of 10 mm (0.39 in) of webbing is introduced into the retractor, it will unlock and function again. Please demonstrate this action to your customer. After an explanation and demonstration, most customers should be able to unlock the retractor without a problem. You may give a copy of this bulletin to your customer for further reference. Disclaimer Page 6098 Electrical Symbols Part 2 Page 2617 Fuse Block: Locations Fuse Block - Underhood Fuse Block Underhood Locations View Located in the underhood compartment above the left front wheel well. Page 37 Description and Operation Power Door Lock Switch: Description and Operation The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Page 14125 10. Remove the inboard retainer screw. 11. Remove the inboard retainer (1) from the headliner. 12. If the vehicle is equipped with lighted sunshades, perform the following steps. 12.1. Reach above the headliner to access the electrical connector (1). 12.2. Remove the electrical connectors from the headliner substrate. 12.3. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. Installation Procedure 1. If the vehicle is equipped with lighted sunshades, perform steps 2 through 8. 2. Lower the headliner in order to gain access to the wire harness. 3. Position the sunshade to the headliner. 4. Connect the sunshade electrical connector to the headliner harness. Page 8960 Brake Caliper: Technical Service Bulletins Brakes - Rear Caliper Mounting Bolt Torque Revision Bulletin No.: 04-05-23-003 Date: April 22, 2004 SERVICE MANUAL UPDATE Subject: Revised Rear Brake Caliper Bracket Mounting Bolt Fastener Specification Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2004 Isuzu Ascender This bulletin is being issued to revise the fastener tightening specification for the rear brake caliper bracket mounting bolt in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The revised specification is as follows: Rear Brake Caliper Bracket Mounting Bolt - 200 N.m (147 lb ft) Disclaimer Page 12666 Electrical Symbols Part 8 Page 15569 16532714 Buick and Oldsmobile --New P/N 16532715 GMC --New P/N 16532716. ^ If the part number printed on a circuit board IS one of the part number listed above, then the circuit board is the new design and does NOT need to be replaced. ^ If the part number printed on a circuit board is NOT one of the part numbers listed above, then the circuit board is the old design and MUST BE REPLACED. Proceed to the next step if either circuit board needs to be replaced. 5. Turn on the tail lamps, directional signals, etc. and determine if there are any bulbs that require replacement. 6. Disconnect the electrical connector from the circuit board being replaced. 7. Remove the three screws attaching the circuit board to the tail lamp and remove the circuit board. 8. Install a NEW stop lamp bulb in a NEW circuit board. ^ On Chevrolet, Buick, and Oldsmobile vehicles, the stop lamp bulb is located in the UPPER (top) socket in the circuit board. ^ On GMC vehicles, the stop lamp bulb is located in the LOWER (bottom) socket in the circuit board. 10. Important: This recall will cover the cost of replacing the stop lamp bulb(s). All other bulbs that require replacement are to be submitted under the normal warranty operation, if applicable. 11. Transfer the remaining bulbs from the old circuit board to the new circuit board. Replace any burned out bulbs. 12. Connect the electrical connector to the new circuit board(s). 13. Turn on the tail lamps, directional signals, etc. and verify that all bulbs are functional. 14. Install the circuit board to the tail lamp and install the three screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 15. Install both the left and the right tail lamp assemblies to the body and install the screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 16. Close the liftgate. Page 4104 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 9999 1. Attach the J 43485 to the J 35555 or equivalent. 2. Place the J 43485 on or in the pump reservoir filler neck. 3. Apply a vacuum of 68 kPa (20 in Hg) maximum. 4. Wait 5 minutes. 5. Remove the J 43485 and the J 35555. 6. Verify the fluid level. 7. Reinstall the pump reservoir cap. 8. Start the engine. Allow the engine to idle. 9. Turn off the engine. 10. Verify the fluid level. 11. Start the engine. Allow the engine to idle. Notice: Do not hold the wheel against the stops while bleeding the system. Holding the steering wheel against wneel stops wil cause high system pressure, overheating, and damage to the pump and/or gear. 12. Turn the steering wheel 180 - 360 degrees in both directions five times. 13. Switch the ignition OFF. 14. Verify the fluid level. 15. Repeat steps 1-14. 16. Reinstall the pump reservoir cap. 17. Clean any spilled fluid. 18. Remove the fender covers. 19. Close the hood. 20. Lower the vehicle. 21. Test the vehicle to verify that the steering functions normally and is free from noise. Page 2409 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic convener. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 280 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 14258 Seat Lumbar Motors And Position Sensors Assembly - Driver Seat Horizontal Motor - Driver/Passenger Power Steering - Whine Noise on Start Up Technical Service Bulletin # 01-02-32-005 Date: 010601 Power Steering - Whine Noise on Start Up File In Section: 02 - Steering Bulletin No.: 01-02-32-005 Date: June, 2001 TECHNICAL Subject: Whine Noise From Power Steering (P/S) System During Vehicle Start-up at Low Ambient Temperatures (Flush/Bleed P/S System, Change P/S Fluid) Models: 2002 Chevrolet and GMC S/T Utility Models (New Body Style) 2002 Oldsmobile Bravada With 4.2L 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on whine noise from the P/S system during vehicle start-up at low ambient temperatures (approximately -12°C (10°F) and lower). Cause In cold ambient temperatures, the P/S fluid thickens in the same manner as any other petroleum based oil. Because of the length of the P/S lines, the thickened oil causes the pump to be noisy during cold start-up. Correction Flush and Bleed the P/S system. Replace the P/S fluid with Cold Climate power steering fluid. Follow the service procedure listed below in order to flush and bleed the P/S system. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 81 For vehicles repaired under warranty use, the table. Disclaimer A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 10988 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TrailBlazer, Envoy, and Bravada TOOLS REQUIRED ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Loosen the evaporator tube (6) from the evaporator. 3. Remove the evaporator tube nut from the condenser. 4. Remove the nuts (1,5) retaining the evaporator tube to the fender. 5. Remove the washer solvent container. 6. Remove the coolant recovery tank. 7. Remove the evaporator tube using J 26549-E. 8. Remove the O-ring seal and discard. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the evaporator tube. Connect the evaporator tube to the evaporator. Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Recall - Transfer Case/Control Module Check & Reprogram Technical Service Bulletin # 01064 Date: 011001 Recall - Transfer Case/Control Module Check & Reprogram File In Section: Product Recalls Bulletin No.: 01064 Date: October, 2001 PRODUCT SAFETY RECALL SUBJECT: 01064 - TRANSMISSION TRANSFER CASE - INSPECT/REPROGRAM MODELS: CERTAIN 2002 4WD CHEVROLET TRAILBLAZER AND GMC ENVOY CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with four wheel drive. The calibration of the active transfer case control module or a range shift collar that was not machined properly may cause insufficient high speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning. A ratcheting noise when the vehicle is in reverse gear or when the driver releases the accelerator pedal while the vehicle is in a drive gear, is a symptom of insufficient gear engagement. CORRECTION Dealers are to perform a "clean neutral" test, as described in this bulletin, to detect vehicles with range shift collars that were not machined properly. If a ratcheting noise is detected during the test, dealers are to replace the transfer case. Less than 1% of the tested vehicles will require a transfer case replacement. Dealers are to update the active transfer case control module (ATCM) calibration on all vehicles in order to increase gear engagement. VEHICLES INVOLVED Involved are certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning campaign repairs. (Not all vehicles within the above breakpoints may be involved.) Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 1649 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Page 3222 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot-taken from the Snapshot menu choice ^ Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Page 5217 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12826 Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper Removal Procedure 1. Remove the front fascia. 2. Remove the bolts (1) that retain the fascia support rods (2) to the impact bar (5). 3. Remove the fascia support rods from the impact bar. 4. Remove the bolts (1) that retain the impact bar to the frame (2). 5. Remove the impact bar (3) from the frame. 6. Remove the tow hooks from the impact bar. Installation Procedure 1. Install the tow hooks to the impact bar. 2. Position the impact bar (3) to the frame (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts (1) that retain the impact bar to the frame. Tighten the bolts to 85 N.m (63 lb ft). Page 697 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. 10. With an upward motion, remove the BCM (1) from the rear electrical center. Service and Repair Grille: Service and Repair Grille Replacement (Chevrolet) Removal Procedure 1. Use a flat-bladed tool in order to release the clips that retain the grille to the headlamp panel. 2. Remove the grille from the vehicle. Installation Procedure 1. Install the grille to the vehicle. 2. Align the retaining clips on the grille with the slots in the headlamp panel assembly. 3. Fully install the retaining clips into the headlamp panel. Page 15792 Conversion - English/Metric Page 7013 For vehicles repaired under warranty, use the table. Disclaimer Page 13124 2. Install the top regulator retaining bolt (1) through the keyhole slot (5) in the rear door inner panel. 3. Install the 2 lower regulator retaining bolts (2,3). Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the bolts in the following sequence. 1. Tighten the lower regulator retaining bolt (3) to 10 N.m (89 lb in). 2. Tighten the upper regulator retaining bolt (1) to 10 N.m (89 lb in). 3. Tighten the middle regulator retaining bolt (2) to 10 N.m (89 lb in). 5. Connect the regulator cable retainer (4) on the door. 6. Connect the electrical connector to the rear window regulator motor. 7. Remove the tape and position the rear window to the regulator glass carrier plate. 8. Loosely tighten the regulator glass carrier bolts (2). 9. Operate the window upward to the full up position, ensuring the window remains in the run channels. Tighten the regulator glass carrier bolts (2) to 10 N.m (89 ft 16 in). Install the water deflector. Install the trim panel. Page 10611 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 10751 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Seat Front Vertical Motor - Driver/Passenger Seat Front Vertical Motor - Driver/Passenger Evaporator Core - Auxiliary Evaporator Core: Service and Repair Evaporator Core - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the heater core-auxiliary. 2. Remove the inverted torx studs from the evaporator block-auxiliary. 3. Remove the backing plate (1) from the evaporator core. 4. Remove the screws from the blower motor control processor-auxiliary. 5. Remove the blower motor control processor-auxiliary. 6. Remove the screws from the HVAC module-auxiliary case sump (2). 7. Remove the HVAC module-auxiliary case sump (2). Page 12565 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 14837 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 6812 9. Remove the servo cover retaining ring. 10. Remove the J 29714-A. 11. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 12. Remove the 2-4 servo from the transmission. 13. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure ^ Tools Required J 29714-A Servo Cover Depressor Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 4203 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Page 6795 15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. ^ Tighten the accumulator cover retaining bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the control valve body. 18. Install the transmission oil pan and filter. 19. Lower the vehicle. 20. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 12512 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Liftglass Ajar Switch Page 14185 2. Remove the 3 bolts that retain the head restraint retractor assembly to the seat back frame. 3. Partially remove the head restraint retractor assembly from the frame. 4. Remove the release cable by sliding the cable retainer over to the large access hole and removing the cable from the head restraint retractor assembly. 5. Remove the retractor assembly from the seat back frame. Installation Procedure 1. Position the head restraint retractor assembly to the seat back. 2. Install the release cable through the head restraint retractor assembly access hole and sliding the cable retainer into position. Notice: Refer to Fastener Notice in Service Precautions. Page 9304 ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Page 10165 The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 2. Turn the steering wheel so that the front wheels are pointing straight ahead. 3. Turn the ignition switch to the lock position and remove the key. 4. Lock the steering column through the access hole in the lower steering column trim cover using the J 42640. 5. Raise and support the vehicle. 6. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 7. Remove the lower intermediate shaft to upper intermediate shaft pinch bolt. 8. Disconnect the lower intermediate shaft from the upper intermediate shaft. 9. Lower the vehicle 10. Attempt to duplicate the customer's concern again. ^ If the noise is still present with the intermediate shaft disconnected, DO NOT replace the intermediate shaft. ^ If the noise is not present, continue with the next step. 11. Raise and support the vehicle. Page 9230 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 12299 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 16022 Turn Signal/Multifunction Switch C2 Turn Signal/Multifunction Switch C3 Interior - Console Power Outlet Cover/Seat Interference Seat Cover: Customer Interest Interior - Console Power Outlet Cover/Seat Interference File In Section: OB - Body and Accessories Bulletin No.: 02-08-49-009 Date: October, 2002 TECHNICAL Subject: Interference with Center Console Rear Auxiliary Power Outlet Cover and Rear Seat Cushion (Replace Rear Auxiliary Power Outlet Retainer and Cover) Models: 2002 Chevrolet TrailBlazer 2002 GMC Envoy 2002 Oldsmobile Bravada Built Prior to May, 2002 Condition Some customers may comment on an indentation mark or, in extreme cases, a puncture of the rear left seat cover. When the left rear seat bottom is raised and the seat back is folded down flat, the seat bottom rests against the back of the center console. The auxiliary power outlet cover, located on the back of the center console, contacts the seat bottom. If enough weight or pressure is applied to the seat bottom in this position, the auxiliary power outlet cover may leave an indentation or possibly damage the seat cover. Cause The auxiliary power outlet cover has a raised finger tab. This raised tab on the cover may cause the condition. Correction A new auxiliary power outlet retainer and cover assembly has been developed to correct this condition. The new cover has a smooth surface and no raised tab. Install a new auxiliary power outlet retainer and cover on the affected vehicles. Use the following procedure and the part number listed below. Tools Required J 42059 Cigarette Lighter Socket Remover 1. Remove the AUX PWR 1 Fuse 46 (20 amp) from the rear fuse block. 2. Open the auxiliary outlet cover. Insert the J 42059 into the outlet and position one side of the "T" portion of the tool into the square tab at the rear of the outlet. Then position the opposite end of the "T" into the opposing square tab. 3. Partially (about half way) pull the outlet straight out of the retaining ring. Use your fingers to aid in guiding out the outlet. 4. Using a flat-bladed tool, remove the rear auxiliary audio/heater controller unit above the outlet and let it rest. This will aid in gaining access to the connector at the back of the outlet. 5. Turn the outlet one turn counterclockwise to access the outlet connector locking tabs. Through the controller opening, use a small flat-bladed tool and disengage the locking tabs of the connector and disconnect the connector. 6. Disengage the retainer ring and cover from the mounting hole by turning the retainer ring/outlet assembly back and forth and lining up each of the three tabs on the retainer to the top slot in the mounting hole. Do not force the retainer ring out. 7. Pull out retainer ring and outlet as an assembly. 8. Using the tool, push down in the outlet to release the retainer from the outlet. Remove the retainer ring and cover from the outlet. 9. Remove the tool from the outlet. 10. Position the new retainer ring and cover to the mounting hole. 11. Index the retainer ring cover top notch to the slot in the mounting hole. 12. Install the retainer ring and cover by pressing the retainer ring into the mounting hole until fully seated. Page 1337 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 12348 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 5813 Electrical Symbols Part 6 Page 8374 Important: ^ Make sure the encoder cover (1) is flush or below the surface of the motor housing and fully seated into place. ^ Ensure that the new encoder/harness assembly is fully seated to the encoder sensor. 9. Install a new gasket/cover plate. This should snap into position. Make sure all the tour tabs are FULLY engaged. 10. Install the motor/encoder onto the transfer case using four M8-1.25 X .35 flange head bolts. Tighten Tighten all four bolts to 13.5 to 17.6 N.m (10 to 13 lb-ft). 11. Connect the transfer case motor/encoder wiring harness. 12. Following normal SPS reprogramming procedures, reprogram the transfer case control module with the latest software calibration. 13. Verify that the 4WD system is operational. Parts Information Parts are currently available from GMSPO. Page 9181 Do NOT attach the positive jumper cable to the stud located under the engine compartment fuse block cover. Doing so may blow the fuse resulting in various interior electrical system conditions. Disclaimer Page 2182 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement- Left Rear Transfer Case Speed Sensor Replacement- Left Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the speed sensor to 17 Nm (13 ft. lbs.). 2. Connect the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Page 270 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 8368 Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Disclaimer Page 3603 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Page 3147 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 13044 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Page 15780 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 5534 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This can be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. DISCLAIMER Page 3286 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 3148 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 774 Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM mounting studs (1) to the intake manifold, if necessary. Tighten Tighten the studs to 6 N.m (53 lb in). Install the PCM (2) to the intake manifold. 2. Install the PCM mounting nuts and bolts (3). Tighten Tighten the nuts and bolts to 10 N.m (89 lb in). 3. Install the PCM harness connectors (3) to the PCM (2). 4. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 5. If a new PCM is being installed, the PCM must be programmed. See: Testing and Inspection/Programming and Relearning Procedures Body Control Module: Procedures IMPORTANT: If the module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not property configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to Programming Theft Deterrent System Components in Theft Deterrent for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 14787 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. Page 9892 WIRES if they are twisted. ^ Remove wire in cavity A and insert the Light Blue wire. ^ Remove wire in cavity B and insert the Dark Blue wire. ^ Remove wire in cavity C and insert the Dark Green wire. ^ Remove wire in cavity D and insert the Orange wire. 40. Reinstall the CPA, reconnect the 8-way connector and reattach it to its retaining clip. 41. Reposition the rear electrical center through the carpet and reposition the carpet. 42. Reinstall the rear electrical center bracket and tighten the retainers. Tighten Tighten the rear electrical center retaining nuts to 10 N.m (89 lb in). 43. Reconnect the negative battery cable. Tighten Tighten the battery ground (negative) terminal bolt to 17 N.m (13 lb ft). 44. Insert the ignition key and turn to the RUN position. Verify radio operation. If all is in working order, proceed to the next step. Otherwise, check your work. 45. Turn the key OFF. Remove the key. 46. Reinstall the rear seat backrest and seat cushion assemblies. Tighten Tighten all of the rear seat back rest and seat cushion retaining nuts to 45 N.m (33 lb ft). 47. Reinstall the jack handle base (tool carrier). Tighten Tighten the nuts to 7 N.m (62 lb in). 48. Reinstall the rear electrical center cover. 49. Reconnect the electrical connectors to the IP trim plate, position the IP trim plate and install the retaining screws. 50. Reinstall the knee bolster (TrailBlazer). 51. Reinstall the closeout/insulator panel (TrailBlazer). 52. Reinstall the center IP carpet lower trim panel and install the screws (except TrailBlazer). 53. Reinstall the console to the vehicle and install the retainers. 54. Reinstall the shift boot and handle assembly. 55. Reinstall the console bin and retainers. 56. Reinstall the first lock pillar trim and carpet retainers to both door openings. 57. Position the driver's seat assembly in the vehicle, connect the wiring and install the retainers. Tighten Tighten the retaining nuts to 45 N.m (33 lb ft). A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Page 9911 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 1712 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Audio System - Poor Radio Reception/Station Drifting Antenna Cable: All Technical Service Bulletins Audio System - Poor Radio Reception/Station Drifting Bulletin No.: 05-08-44-016A Date: March 15, 2006 TECHNICAL Subject: Poor Radio Reception or Radio Will Not Stay On Station (Check Antenna Coax Cable Connection and/or Install Antenna Cable Extension) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2004-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2006 GMC Envoy Denali, Envoy Denali XL 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Attention: Vehicles built after December 21, 2004 were produced with the radio antenna extension cable already installed. Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add models and provide another cause for the condition. Please discard Corporate Bulletin Number 05-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on poor radio reception or that the radio will not hold the station. This occurs on either AM or FM bands. Cause The antenna coax cable connection behind the glove box door may not be fully seated or incorrect radio coax impedance. Correction Inspect the antenna coax cable connection and/or install an antenna extension cable, P/N 15267997, using the following procedure. 1. Remove the right closeout/insulator panel from the IP. 2. Verify that the antenna coax cable connection leads are fully seated. 3. If the leads are fully seated, separate the connection and install an antenna extension cable, P/N 15267997, between the two leads. 4. Install the right closeout/insulator panel to the IP. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1763 ^ Rewrap the conductors with the mylar tape. ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Page 11352 Disclaimer Page 8507 3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic. 4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3). 5. Install the washer and snap ring retaining the motor/encoder rotary position sensor. 6. Install the motor/encoder gasket (1). Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD Control Module: All Technical Service Bulletins Drivetrain - Shudder/Binding/Feels Like Stuck in 4WD File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-008A Date: February, 2003 TECHNICAL Subject: Shudder, Rocking Motion, Binding, Feels Like Vehicle is Stuck in 4WD (Crow Hop) When Turning at Low Speeds (Replace Transfer Case Encoder Sensor and Reprogram TCCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada This bulletin is being revised to update the service procedure and incorporate the fluid exchange. Please discard Corporate Bulletin Number 02-04-21-008 (Section 04 - Driveline Axle). Condition Some customers may comment that when turning, the vehicle feels like it is binding, or the vehicle feels like it is stuck in 4WD (crow hop), or that the 4WD system is not working correctly. A shudder type sensation is felt. Technician Diagnosis This intermittent condition may be difficult to duplicate. The potential is there at all times for the Bravada. The potential is only present in the Auto Mode of the transfer case with the TrailBlazer or Envoy. Correction Important: It is extremely important to check all of the tires before repairs are attempted for these types of customer concerns. Mismatched tires may cause these type of customer concerns. Inspect the tires in the following areas: ^ Ensure that the tires are inflated to the recommended tire pressure as listed on the tire placard on the driver's door. ^ Use a tire tread depth gauge to determine the tread depth. The tire tread depth must be nearly equal on all four corners of the vehicle. ^ Ensure that the tires are all the same brand, size, and tread design. Important: Pay particular attention so that the proper parts are replaced. The parts terminology is somewhat confusing. You will be replacing the encoder (sensor) and gasket not the complete motor assembly. Currently, the General Motors Parts Catalog lists the following names: ^ Motor Asm, Trfer Case Encoder (This is the Encoder (Sensor). It looks like a donut with three (3) contacts on one side). ^ Gasket. ^ Actuator Asm, Trfer Case Four Whl Drv (This is the complete motor assembly consisting of the Motor and housing, the Motor Asm, the Trfer Case Encoder (Sensor), and the gasket). Use the following procedure to replace the Motor Asm, Trfer Case Encoder (Sensor) and Gasket. 1. If the vehicle is a TrailBlazer or Envoy, place the 4WD selector switch in the 2 HI position. 2. Raise the vehicle. 3. Disconnect the wiring harness connector at the top of the transfer case. Page 9444 connector/leads on the body harness by splicing in the service pigtail, P/N 15306403, using the procedure listed below. Passenger Door 1. Inspect the passenger door harness connector (9 wires) and terminals (inline to body harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If the terminals or connector show signs of corrosion, replace the door harness. Refer to the Front Door Wiring Harness Replacement procedure in the Doors sub-section of the Service Manual. Ensure the replacement door harness has unused cavities blocked. 2. Inspect the body harness connector (9 wires) and terminals (inline to passenger door harness). ^ If there is no evidence of corrosion, verify that the three empty cavities of the plastic connector are properly blocked. If two cavities are open, clean the connector using an electrical contact cleaner and fill the two open/unblocked cavities using RTV. ^ If there is evidence of corrosion, replace the mating connector/leads on the body harness by splicing in the service pigtail, P/N 88953131, using the procedure listed below. Service Pigtail Procedure 1. Remove the closeout/insulator panel. 2. Remove the door sill plate. 3. Pull back the carpet for access. 4. Remove the driver foot rest pad. 5. Release the harness to body clips. 6. Pull the existing body harness through the door jam and into the body. 7. Cut the existing harness and splice in the service pigtail. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. 8. Feed the harness through the body and into the door jam. 9. Install the harness to body clips. 10. Install the driver foot rest pad. 11. Install the carpet in place. 12. Install the door sill plate. 13. Install the closeout/insulator panel. Page 4331 deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter Recall 01V334000: Transfer Case Control Module Update Control Module: All Technical Service Bulletins Recall 01V334000: Transfer Case Control Module Update DEFECT: On certain sport utility vehicles equipped with 4-wheel drive, the calibration of the transfer case control module could cause insufficient high-speed gear engagement. If the gear is not engaged, the vehicle can roll when the transmission is in "park," and a crash could result without warning. REMEDY: Dealers will update the transfer case control module calibration to increase gear engagement. The manufacturer has reported that owner notification began Nov. 6, 2001. Owners who do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782. Page 11733 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 10888 Control Module HVAC: Diagrams HVAC Systems - Automatic Blower Motor Control Module Blower Motor Control Processor - Auxiliary Page 4512 Intake Air Temperature (IAT) Sensor Page 15548 Page 11452 Tighten the screws to 3 Nm (26 lb in). 44. Reposition the seat switch bezel to the side of the seat cushion and install the screws. Tighten Tighten the screws to 3 Nm (26 lb in). 45. If equipped, install the lumbar support knob. 46. If equipped, install the recliner handle and screw. Tighten Tighten the screw to 3 Nm (26 lb in). 47. Connect the side impact air bag electrical connector under the seat. 48. Install the SIR fuse. 49. Turn the ignition switch to the ON position and verify that the SIR light flashes seven times and goes out. 50. For U.S. and Canada: All replaced seat belt retractors are to be held until a return request is received from the GM Warranty Parts Center (WPC). Page 10045 Flushing the Power Steering System 1. Turn off the engine. 2. Open the hood. 3. Install fender covers. 4. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to the Lifting and Jacking the Vehicle procedure in the General Information subsection of the Service Manual. 5. Place a large container under the fluid return hose in order to collect the draining fluid. 6. Remove the fluid return hose at the P/S pump inlet underneath the reservoir by removing the clamp with a pair of pliers. 7. Drain the P/S fluid from the reservoir. 8. Plug the reservoir return hose inlet connection on the P/S pump reservoir. Important: ^ Do not run the engine without the P/S fluid level at FULL COLD. ^ This step will require 4 L (4 qt) of Cold Climate power steering fluid. 9. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid, P/N 12345866 (in Canada, use P/N 10953484) 0.5 L (16 ounce), or P/N 12345867 (in Canada, use P/N 10953471) 1.0 L (32 ounce). 10. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using 4 L (4 qt) Cold Climate power steering fluid. Notice: Do not hold the wheel against the stops while flushing the system. Holding the steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 11. Turn the steering wheel from stop to stop. 12. Continue draining until all of the old fluid is cleared from the P/S system. 13. Turn off the engine. 14. Remove the plug from the pump reservoir inlet connection. 15. Install the fluid return hose to the pump reservoir. 16. Fill the P/S reservoir to the FULL COLD mark with Cold Climate power steering fluid. Bleeding the Power Steering System Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Page 4015 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Cooling System - Electro-Viscous Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Cooling System - Electro-Viscous Fan Clutch Operation Bulletin No.: 06-06-02-003 Date: February 14, 2006 INFORMATION Subject: Operating Characteristics of the Electro-Viscous (EV) Fan Clutch and Diagnostic Tips for Cooling Fan Noise, Delayed Transmission Shifts and/or Engine Revving Too High Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X with 4.2L I-6, 5.3L V-8 or 6.0L V-8 Engine (VINs S, P, M, H - RPOs LL8, LM4, LH6, LS2) Date/VIN Breakpoints for Vehicles with New EV Fan Clutch Vehicles built after and including the Date or VIN Breakpoints listed in the table shown are equipped with the new electro-viscous (EV) fan clutch. Vehicles of any model year listed in "Models Affected" with labor code J3390 (claimed after June 8, 2005) with P/N 15293048 in Claim History may also be equipped with this new EV fan clutch. After having service for poor HVAC performance and/or engine cooling performance, some vehicles may exhibit fan noise, delayed transmission shifts, or the engine revving too high. These conditions may be caused by expected operating characteristics of the new design electro-viscous (EV) fan clutch. This new design EV fan clutch has been installed on production vehicles from the end of 2005 model year production (June 2005) and all 2006 model year vehicles. The new design EV fan clutch may also be present on vehicles serviced with this new part per Corporate Bulletin Number 04-01-38-019A or for other service related conditions. The updated design of the electro-viscous (EV) fan clutch helps improve A/C performance but may also produce some additional fan engagement noise. Important: Unless a specific issue is identified by proper SI diagnosis, do NOT replace a fan clutch for fan noise. Page 4587 Conversion - English/Metric Page 6304 2. Install the transfer case in the vehicle. 3. Install the transfer case mounting nuts. Tighten the nuts to 47 Nm (35 lb ft). 4. Remove the transmission jack stand. 5. Install the transfer case speed sensors electrical connectors. 6. Install the vent hose. 7. Install the motor/encoder electrical connector. 8. Install the transfer case harness to the transfer case. 9. Install the transfer case wiring harness to the retainers. 10. Install the fuel lines to the retainer. 11. Install the rear propeller shaft. ^ Install the propeller shaft into the transfer case. ^ Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 12. Install the front propeller shaft. ^ Install the propeller shaft to the transfer case. ^ Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal. ^ Install the yoke retainers and the bolts. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the fuel tank shield. 14. Install the fuel tank shield retaining bolts. Tighten the bolts to 25 Nm (18 lb ft). 15. Lower the vehicle and continue with Active Transfer Case Control Module reprogramming. Active Transfer Case Control Module Reprogramming 1. Reprogram the transfer case control module with calibration P/N 12575794. A. Connect the scan tool to the vehicle. B. Power-up the scan tool and select the Service Programming feature. C. Select the appropriate vehicle. D. Press the Request Info button on the scan tool. E. Connect the scan tool to the computer station. F. Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). G. Select "vehicle" from the selection menu. H. Select "ATC Active Transfer Case Module" to program. I. Select "Normal" for Programming Type. J. Select the applicable software calibrations. Service Precautions Trunk / Liftgate Shock / Support: Service Precautions CAUTION: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. Page 1756 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Page 1462 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 9156 For vehicles repaired under warranty, use the table. Disclaimer Page 7459 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. 9. Install the drive axle nut. Tighten the drive axle nut to 140 Nm (103 ft. lbs.). 10. Install the tire and wheel center cap. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 11235 8. If the steering wheel has PAD control, install the wire harness assembly. Refer to Steering Column Wire Harness Assembly Replacement. 9. Install the wire harness strap. 10. Install the upper and lower trim covers. 11. Install the steering wheel to the column. 12. Enable the inflatable restraint steering wheel module. Page 6182 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 8237 1. Align the input shaft seal on the input shaft. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case assembly. 4. Inspect the transfer case fluid level. 5. Lower the vehicle. Refer to Vehicle Lifting. Page 5333 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Page 3048 6. Remove the right and the left upper engine mount nuts. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the right and the left lower engine mount nuts. 9. Remove the engine protection shield mounting bolts. 10. Remove the engine protection shield. Important: When placing jack onto the oil pan, pay close attention to not damaging the oil level sender. 11. Lower the vehicle and place a floor jack under the oil pan with a block of wood. 12. Raise the engine with the jack just enough to clear the engine mount studs. 13. Remove the right engine mount from the bracket. Page 6791 ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin 12. Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1 ) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following defects: ^ Porosity ^ Cracks Propshaft Speed Sensor - Front Specifications Engine Oil Pressure: Specifications Oil Pressure (At the sending unit) Warm - Minimum 12 psi - 1200 RPM Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test ^ Tools Required J 35667-A Cylinder Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the diagnosis. The cylinder leakage test may be used in conjunction with the engine compression test, to isolate the cause of leaking cylinders. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the battery ground (negative) cable. 2. Remove the spark plugs. 3. Install J 35667-A. 4. Measure each cylinder on the compression stroke, with the valves closed. Important: It may be necessary to hold the crankshaft balancer bolt, to prevent piston movement. 5. Apply air pressure, using J 35667-A. Refer to the manufacturer's instructions. 6. Record the cylinder leakage readings for each cylinder. Important: ^ Normal cylinder leakage is from 12 to 18 percent. ^ Make a note of any cylinder with more leakage than the other cylinders. ^ Any cylinder with 30 percent leakage or more requires service. 7. Inspect the four primary areas, to properly diagnose a leaking cylinder. 8. If air is heard from the intake or exhaust system, perform the following procedure: ^ Remove the camshaft cover. Ensure the valves are closed. - Inspect the cylinder head for a broken valve spring. ^ Remove the cylinder head and inspect. 9. If air is heard from the crankcase system at the crankcase (oil filler tube), perform the following procedure: ^ Remove the piston from the suspect cylinder. ^ Inspect the piston and connecting rod assembly. ^ Inspect the engine block. 10. If bubbles are found in the radiator, perform the following procedure: ^ Remove the cylinder head and inspect. ^ Inspect the engine block. 11. Remove the J 35667-A. 12. Install the spark plugs. 13. Install the battery ground (negative) cable. Page 5790 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Instruments - Gauges Inoperative/Read Zero at Times Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Read Zero at Times File In Section: 08 - Body and Accessories Bulletin No.: 02-08-49-004A Date: November, 2002 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Read Zero at Times, Gauges Inoperative at Times (Reprogram IPC) Models: 2002 Chevrolet TrailBlazer, TrailBlazer EXT 2002 GMC Envoy, Envoy XL 2002 Oldsmobile Bravada This bulletin is being revised to change the service procedure. Please discard Corporate Bulletin Number 02-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that at times all the IPC gauges are inoperative or read zero at times. Cause The PC cluster module receives information to position the gauges when the key is turned from OFF to ON/START. Random electrical interference with this data information on the serial data line may interrupt the receipt of the information by the IPO. When the IPC data information signal is compromised, the IPC will set the gauges to zero for that complete ignition cycle. The gauges may work properly on the next ignition cycle, if the ignition was off for approximately five minutes prior to the next ignition cycle. Diagnostic Aid With the Tech 2(R), determine the IPC software part number using the following procedure. 1. Connect the Tech 2 to the vehicle. 2. Power up the Tech 2. 3. From the main menu, Press Enter. 4. Select F0: Diagnostics. 5. Select the correct model year. 6. Select: Ld Trk. 7. Select F1: Body 8. Select the proper vehicle line 9. Select the proper name plate. 10. Select the HVAC type. 11. Select Instrument Panel Cluster. 12. Select F4: ID Information. 13. Select F1: Module Information 2 14. It the IPC software part number is 09363270 or 15085477, re-program the IPC. Page 3863 ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Control Module: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 14591 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 6111 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 GM Oil Life System (TM) - Resetting Maintenance Reminder Control Module: Technical Service Bulletins GM Oil Life System (TM) Resetting File In Section: 00 - General Information Bulletin No.: 02-00-90-001 Date: March, 2002 INFORMATION Subject: GM Oil Life System(TM) - Resetting Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada These vehicles have an oil life monitor. The GM Oil Life System(TM) will show when to change the engine oil and oil filter. The GM Oil Life System(TM) must be reset after changing the engine oil and oil filter. Resetting Procedure The current Owner's Manual contains the following reset procedure: 1. Turn the ignition to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENG OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. However, it has been found that after completing the reset procedure, the CHANGE ENG OIL light does not flash as stated in the vehicle Owner's Manual. If the CHANGE ENG OIL light goes out after the reset procedure and does not return after the next ignition cycle, then the system has been reset. If the vehicle is equipped with a Driver Information Center (DIC), then reset confirmation can also be done by verifying that the Engine Oil Life percentage value has reset to 100%. Use the above information to prevent the inadvertent replacement of the instrument cluster if there are comments that the oil life reset feature does not work. Disclaimer Page 10362 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Drivetrain - Transfer Case Grinds In 4WD/AWD Transfer Case Actuator: Customer Interest Drivetrain - Transfer Case Grinds In 4WD/AWD TECHNICAL Bulletin No.: 08-04-21-001B Date: August 25, 2008 Subject: NVG 126/226 Transfer Case Grating/Grinding Noise When 4WD is Engaged, Service 4WD Lamp On, DTC C0327 Set (Replace Clutch Pressure Plate Bearing Assembly and Clutch Lever) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (NP8) Transfer Case Built Prior to September 18, 2007 (NVG 126) or September 21, 2007 (NVG 226) Supercede: This bulletin is being revised to update the correction information to include a procedure to reindex the transfer case encoder motor (actuator). This procedure is being provided to help reduce unnecessary warranty expenses. Please discard Corporate Bulletin Number 08-04-21-001A (Section 04 - Transmission/Transaxle). Condition Some customers may comment on a grinding type noise in the transfer case when 4WD is engaged in either AUTO or 4WD mode. This noise may also be accompanied by the SERVICE 4WD lamp being illuminated and DTC C0327 set. This condition is more prevalent on vehicles where 4WD is continuously used. Cause This noise may be caused by a faulty clutch pressure plate bearing. Correction A more robust clutch pressure plate bearing, inner plate and clutch lever has been released for service. Replace the clutch pressure plate bearing, inner plate and clutch lever. Refer to the Transfer Case Disassemble and Transfer Case Assemble procedures in SI. Former and new parts should not be intermixed during transfer case overhaul and they are to be used in sets only. DO NOT replace the transfer case assembly unless extensive internal damage has occurred. Important: When the clutch pressure plate bearing fails, it causes the clutch lever to over-travel, allowing the transfer case encoder motor (actuator) to rotate to an invalid position. Engineering has developed a tool and procedure to reindex the transfer case encoder motor (actuator) so it can be reused. Use the specific procedure listed below. NVG 126 Transfer Case Encoder Motor (Actuator) Indexing Procedure Tools Required: ^ (1) EL-49741 9 Volt Encoder Motor (Actuator) Jumper Harness (Tool can be obtained from SPX/Kent Moore. ^ (2) J-356165 Terminal Test Adapter (Test Probe) Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J43631 Ball Joint Remover Removal Procedure 1. Remove the tire and wheel center cap. 2. Remove the drive axle nut. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel. 5. Remove the wheel hub and bearing. 6. Remove the outer tie rod retaining nut. Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Transfer Case Actuator: Customer Interest Drivetrain - 4X4 Lamp Flashing/4WD Inoperative/DTC's Set Bulletin No.: 04-04-21-004 Date: December 16, 2004 TECHNICAL Subject: 4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0550 Set (Replace Transfer Case Encoder Sensor, Reprogram TCCM) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Four-Wheel Drive (4WD) Condition Some customers may comment that the Service 4WD light is on, the 4WD system is inoperative or the 4WD switch indicator lights are blinking. Service Diagnosis Technicians may find DTC C0327 in the Transfer Case Control Module (TCCM). This would indicate an encoder sensor malfunction. It is also possible that the module may be in a mode that will not allow any shifts or updates for the software or calibrations. If this occurs, the TREC fuse (in the engine compartment) must be pulled and reinstalled after 30 seconds. This should allow further operation and service of the system. If a C0550 code is found, this is an unrelated concern and SI diagnostics should be followed for this concern. Correction Important: Carefully handle and install the new encoder. Improper installation of the encoder could result in a repeat failure. 1. Raise the vehicle. 2. Disconnect the transfer case motor/encoder wiring harness. 3. Remove the four bolts that secure the motor/encoder to the transfer case. 4. Remove the motor/encoder from the transfer case. 5. Remove the black plastic gasket/over plate from the motor/encoder. Page 5685 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Fuse Types Part 1 Body - Liftgate Binding/Improper Fit/Rear Glass Broken Trunk / Liftgate Hinge: All Technical Service Bulletins Body - Liftgate Binding/Improper Fit/Rear Glass Broken Bulletin No.: 06-08-66-011A Date: November 08, 2006 TECHNICAL Subject: Rear Liftgate Binds, Improper Fit, Broken Liftgate Glass (Install Welds and Bumpers) Models: 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL Supercede: This bulletin is being revised to add part number information. Please discard Corporate Bulletin Number 06-08-66-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the liftgate or the liftgate glass doesn't fit properly. In some extreme cases, the rear liftgate glass may have broken. Cause A couple of welds may have broken around the upper liftgate hinge(s) or a crack may have formed around the inner two welds. Remove the liftgate and inspect the inner to outer panel welds at the upper hinges. Correction Remove the liftgate trim and electrical wiring from the liftgate. Remove the liftgate and liftgate glass from the vehicle. Straighten the sheet metal at the hinges. Drill four 5/16" holes through the inner panel at the four locations shown in the illustration above. Prepare the sheet metal around the four holes for welding. Clamp the inner and out panel together. Page 8806 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 3842 Electrical Symbols Part 1 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 5988 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: Customer Interest Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure.